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CROSS REFERENCE TO RELATED APPLICATIONS
This is a continuation of prior application Ser. No. 08/970,026, filed on Nov. 13, 1997, now abandoned, which is a continuation in-part of Ser. No. 08/717,184, filed on Sep. 20, 1996, now U.S. Pat. No. 6,056,703, which is a continuation-in-part of 08/649,081, filed on May 17, 1996, now abandoned, which is a continuation-in-part of 08/627,309, filed on Apr. 3, 1996, now abandoned.
BACKGROUND OF THE INVENTION
The invention relates in general to a method and apparatus for characterizing gastrointestinal sounds and in particular to a method and apparatus employing a microphone array attachable to a patient's body for collecting sounds from multiple sources in the body and a computer system for receiving digitized gastrointestinal sound signals and determining the spectra and duration of the sounds and characterizing states of the gastrointestinal tract on the basis of the spectrum and duration.
It has been known in the past to employ electronic analysis of sounds from the gastrointestinal tract as an adjunct to the physician auscultating the gastrointestinal tract in an attempt to determine quickly and with a minimum of diagnostic equipment the condition of the patient. In the past, for instance, as disclosed in U.S. Pat. No. 5,301,679, a method and system was provided for providing diagnostic information for various diseases including diseases of the gastrointestinal tract by capturing body sounds in a microphone placed on the body surface or inserted orally or rectally into the gastrointestinal tract. The spectrum analyzer used a real time audio one-third octave technique using a plurality of analog filters and a peak detector provide a log calculation of envelope amplitudes. Other systems also used microphones sensitive to specific frequency ranges and are exemplified by Dalle, et al. “Computer Analysis In Bowel Sounds,” Computers in Biology and Medicine February 1975 4(3-4) pp. 247-254; Sugrue et al., “Computerized Phonoenterography: The Clinical Investigation of the New System,” Journal of Clinical Gastroenterology , Vol. 18, No. 2, 1994, pp. 139-144; Poynard, et al., “Qu'attendre des systemes experts pour le diagnostic des troubles fonctionnes intestinaux,” Gastroenterology Clinical Biology , 1990, pp. 45C-48C. Also of interest are U.S. Pat. Nos. 1,165,417; 5,010,889; 4,991,581; 4,792,145. Unfortunately, none of the systems relate to using specific morphological filtering and event characterization of the type which might be able to identify ileus or small bowel obstruction or the like. The prior systems seem to have suffered from the inability to cope with relatively irregular sounds and irregular signals and to pick events of detail from the signal. Many of the systems used averaging techniques on the raw signal, which would tend to obscure the event of interest in noise or other unwanted portions of the signal and thus actually work against the diagnostician attempting to characterize genuine gastrointestinal sounds as opposed to other sounds coming form the body. Thus, it would appear that despite the use of sophisticated spectral techniques and the like the prior art, having been unable to identify events, appeared to operate on relatively noisy data from which it would be difficult to extract meaningful conclusions. Accordingly, what is needed is a system which can quickly and easily identify such conditions.
SUMMARY OF THE INVENTION
The invention is directed to a method and apparatus including a microphone array including three microphones fixed on a mount for precise positioning with respect to key location of the anatomy of the patient with a fourth free microphone which may be placed adjacent to the sternum of the patient for picking up breathing, cardiac and environmental sounds and the like which are to be subtracted from the gastrointestinal sounds and are treated as noise. The microphones feed a sound equalizing system for selection of certain sound frequency ranges which in turn feeds analog sound signals representative of gastrointestinal sounds to a tape recorder. The tape recorder is connectable to a computer which includes an analog to digital converter. Digitized multiple gastrointestinal sounds may then be processed by a computer in accordance with morphological filtering algorithms which characterize both the spectra and the duration of the sounds emanating from the gastrointestinal tract. In addition, the computer can subtract out components of sounds related to the background noise from the surrounding room or from the breathing which is picked up by a free microphone. An output indication may be provided to the physician or other health care worker through a printer or a video display screen which provides an indication as to the type of sound and a characterization in some cases as to the condition of the patient such as ileus and the like.
The present system is particularly characterized by the fact that the initial processing of the digitized audio signals relates to selecting gastrointestinal events of interest from extended noisy audio signals. One way in which this has been done in the present application is to use an amplitude thresholding system to look for events of interest and then to focus additional processing on those events. This approach does not appear to have been taken in the previous systems and may have reduced their ability to extract meaningful data from the relatively noisy environments in which they operate.
Approximately ten percent of the U.S. population has gastrointestinal symptoms each year for which physician consultation is sought. The symptoms include abdominal pain, distension, diarrhea and vomiting. The causes vary from benign conditions such as irritable bowel syndrome or self-limiting viral illness to life-threatening bowel blockage. Current diagnostic methods for determining what is occurring include a host of expensive and invasive tests, including such techniques as CT scans and colonoscopy.
The instant invention provides utility for diagnostic data for conditions involving small bowel obstruction, delayed gastric emptying, inflammatory disorders and motility disorders. For instance, small bowel obstruction, which includes various types of mechanical bowel obstruction, is a common reason for emergency surgical admission to the hospital and results in over 9,000 deaths each year. Signs and symptoms of small bowel obstruction may mimic benign viral or other illnesses. Many patients, especially medically complex subjects also having cancer, diabetes, previous gastrointestinal surgery and sepsis may present diagnostic dilemma of small bowel obstruction versus non-mechanical pseudo-obstruction or ileus. It is critical to distinguish these patients promptly since small bowel obstruction patients typically require surgical intervention while ileus patients are usually managed without surgery. Delay in proper diagnosis may lead to improper and dangerous surgical intervention in the non-obstructive patient or, conversely, may lead to complications or death in those with bowel obstruction. The instant invention provides a rapid, safe, accurate, low cost, lightweight and comfortable apparatus for assisting in small bowel diagnosis.
In addition, the apparatus can determine conditions involving delayed emptying of gastric contents, a condition called gastroparesis, to which millions are subject. Symptoms of gastroparesis include bloating, heartburn, belching, decreased appetite and upper abdominal pain. The preferred diagnosis method is scintigraphy scanning, whereby a liquid or solid meal is labeled with a gamma ray emitting radioisotope, usually radioactive technetium, and counts are obtained using a gamma camera over a period of 60 to 120 minutes. The test is expensive and requires special scheduling.
Inflammatory disorders are the most common of all gastrointestinal disorders and include peptic ulcer disease, viral, bacterial and other infections and the inflammatory bowels disease such as Crohn's disease and ulcerative colitis. Inflammatory changes of the gastrointestinal tract lead to altered mechanical properties including changes in acoustic resonance and reflective characteristics. The instant invention, through the use of its sophisticated signal processing, provides pattern recognition techniques for examining patients for inflammatory disorders.
Motility disorders are a diverse set of less well-defined conditions that pertain to derangement in the control and function of the propulsive or peristaltic activity of the gastrointestinal tract. Gastroparesis is one example of this type of disorder. Again, the instant invention can aid in determining when motility disorders are present.
It is a principal aspect of the present invention to provide a gastrointestinal sound processing system which can characterize individual gastrointestinal events on diagnostic basis.
It is another aspect of the present invention for providing a gastrointestinal sound characterization system which intercepts sounds from multiple locations in the human body for diagnostic purposes.
Other aspects of the present invention will be apparent to one of ordinary skill in the art upon a perusal of the following specification and claims in light of the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of an apparatus embodying the present invention for gastrointestinal sound processing;
FIG. 2 is a block diagram of a computer and associated hardware shown in FIG. 1;
FIG. 3 is a perspective view of a portion of a human torso showing the location of multiple microphones on the torso for picking up gastrointestinal sounds and background noise;
FIG. 4 is an elevational view showing portions of the interior organs of the body in dotted form showing the arrangement of the microphone array on the body;
FIGS. 5 and 6 are upright and upside down perspective views of one of the microphones of the array;
FIG. 7 is a flow diagram of a system for collecting and processing gastrointestinal sounds;
FIG. 8 is a flow diagram of a core process for processing gastrointestinal sounds;
FIG. 9 is a flow diagram of a telemedicine version of the system;
FIG. 10 is a flow diagram of a process for collecting ambulatory gastrointestinal sounds and storing them;
FIG. 11 is a flow diagram similar to FIG. 10 showing use of a multiple channel analog tape recorder in ambulatory settings;
FIG. 12 is a flow diagram related to finding acoustic events and their features;
FIG. 13 is a flow diagram related to localization and characterization of gastrointestinal acoustic events;
FIGS. 14 a and 14 b are flow diagrams for calculating a gastrointestinal sound envelope;
FIG. 15 is a flow diagram for calculating structuring elements;
FIG. 16 is a flow diagram for calculating filter coefficients;
FIG. 17 is a flow diagram for calculating frequency domain Hilbert filter coefficients;
FIG. 18 is a flow diagram for calculating frequency domain band pass filter coefficients;
FIG. 19 is a flow diagram for an envelope smoothing process using dilation;
FIG. 20 is a flow diagram for determining the amplitude threshold;
FIG. 21 is a flow diagram for producing a histogram of the envelope;
FIG. 22 is a flow diagram for calculating a smoothed average slope of the histogram;
FIG. 23 is a flow diagram for finding gastrointestinal sound events in each channel;
FIG. 24 is a flow diagram for pasting neighboring signals on the same channel into a single event;
FIG. 25 is a flow diagram for finding related events in other channels;
FIG. 26 is a flow diagram for determining an interchannel event delay threshold;
FIG. 27 is a flow diagram for finding nearby events and saving their time and amplitude;
FIG. 28 is a flow diagram of a checking process for determining whether a nearest event is part of a related gastrointestinal event;
FIG. 29 is a flow diagram for checking gastrointestinal event overlap on other channels;
FIG. 30 is a flow diagram for localizing each of the gastrointestinal events;
FIG. 31 is a flow diagram for defining sound regions of origin;
FIG. 32 is a flow diagram for determining a sound region of origin;
FIG. 33 is a flow diagram for determining the average transabdominal speed of sound and abdominal damping characteristics;
FIG. 34 is a flow diagram for determining a location of a sound source;
FIG. 35 is a flow diagram for combining event features;
FIG. 36 is a flow diagram for recognizing gastrointestinal events;
FIG. 37 is a flow diagram for recognizing environmental events of the type picked up by the free microphone;
FIG. 38 is a flow diagram for recognizing signals representative of vascular events;
FIG. 39 is a pattern recognition flow diagram;
FIG. 40 is a flow diagram to test whether a subject is a control, has small bowel obstruction or ileus; and
FIG. 41 is a flow diagram for nearest neighbor classification;
FIG. 42 is a flow chart of a method of adaptively filtering a channel signal;
FIG. 43 is a flow chart of specific channel filtering steps of the process shown in FIG. 42;
FIG. 44 is a plot of the number of events versus frequency versus duration from the epigastraeum of a normal subject;
FIG. 45 is a plot of the lower quadrant of a subject with ileus;
FIG. 46 is a plot of a subject with small bowel obstruction;
FIG. 47 is a plot from the lower right quadrant of a normal subject;
FIG. 48 is a plot from the lower left quadrant of a normal subject;
FIG. 49 is a spectrogram of four events in a normal subject; and
FIG. 50 is an event in a subject with small bowel obstruction.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings and especially to FIG. 1, an apparatus for characterizing gastrointestinal sound is generally shown therein and identified by numeral 10 . The apparatus 10 includes a microphone array 12 having a free microphone 14 , an array microphone 16 , a second array microphone 18 and a third array microphone 20 coupled to filter and amplifier 22 which feeds multiple analog signals representative of the gastrointestinal sounds over leads 24 to a Tascam 2000 multichannel tape recorder 26 where the analog signals may be recorded in analog format. The sound signals may then be transferred over lead 28 to a computer 30 for analysis. Following analysis output results may be displayed on a video display terminal 32 or output through a printer 34 .
Referring now to FIG. 2, a block diagram of the computer 30 is shown therein. The computer 30 receives the analog gastrointestinal sound signals on a line 23 at an analog to digital converter. The gastrointestinal signals are digitized and fed over lines 40 to a system bus 42 of the computer 30 . The computer 30 includes a disk controller 44 having connected to it a hard disk drive 46 and a floppy disk drive 48 . The hard disk drive 46 stores a program as represented by the flow charts of FIGS. 7 through 37 inclusive. Upon receipt of sound signals from a patient the software routines are transferred from the hard disk drive 46 through the disk controller 44 to the system bus 42 and are loaded into random access memory 50 connected to the system bus for execution by a microprocessor 52 . Portions of the code and data of the software may be stored from time to time in a cache memory associated with the microprocessor 52 . Read only memory 54 contains operating system information and outputs may be provided from the system bus by a video controller 56 to a video output line 31 connected to the display 32 . Likewise, outputs may be connected through an input/output module, having parallel and serial ports 58 , through a line 33 . The microphone array 12 , as may best be seen in FIGS. 3 and 4, microphones 14 through 20 placed on a torso 70 of a human being with the free microphone 14 being placed near the sternum and the array microphones 15 through 20 attached slidingly to array arms 72 , 74 and 76 . The sliding adjustable microphone harness is necessary to accommodate subjects of a wide variety of sizes. The microphones respectively are located to pick up multiple gastrointestinal sound sources from the human torso to provide analog signals to the computer 30 .
The computer 30 , by execution of the routines shown in FIGS. 7 through 43, inclusive, determines the spectra and the duration of the individual gastrointestinal events and provides an output indication thereof in response to the signal and the variables input as set forth in the tables below. The use of the multiple microphone array in combination with the routines set forth in the flow charts which are executed by computer allows quick and easy analysis of the gastrointestinal sounds for the determination of conditions such as small bowel obstruction, ileus and the like.
Referring now to the drawings and especially to FIG. 7, an overall flow diagram for gastrointestinal sound capture is shown herein wherein in a first step a patient 200 is fitted with the microphone array in a step 202 following which sounds captured by the microphone array 202 are fed to an analog amplifier and filter. Prior to analyzing captured sound the variable set found in Table 2 are in initialized to proper values. Table 2 provides optimized values of these settings for the current hardware and system.
TABLE 1
ABBREVIATIONS
AMP S
Amplitude of structuring elements
BNDFLT
Name of band-pass filter array of
coefficients
chr_mx
Maximum coherence value
cntr
Dummy counter variable
d_c
Duration of current event
dd1, dd2, dd3
Duration of detected events in
other channels
DIST_CLASS
Average distance between subjects
in the same class excluding current
subject
DIST_SUBJ
Average distance between current
subject and other members in the
same class
dly1, dly2, dly3
Interchannel delay, in seconds
DT_LNS
length of data processing array
DT_RD
Number of data points to read from
file
dn
Number of elements
DT_PTS
Number of data points in file
DTRD
Number of data points to read
dr1, dr2, dr3
Duration of related events in other
channels
dur
Event duration
DUR_MED
Median duration for all events
ed, ed1, ed2, ed3
End times of detected events
ENPARR
Name of envelop array
ENPMAX
Envelope value at the envelop
histogram maximum
ENPPOS
Envelop value when histogram slope
first becomes positive
env_val
A point of the digital envelope
data
er, er1, er2, er3
End times of the related event
ev_ch
Channel of current event
EV_RATE
The average event rate during the
recording time
EV_TSR
Event time series
f_dom
Dominant frequency of an event
F_DOM_MED
The median dominant frequency of
all events
FH S
Value of the higher frequency (for
low-pass filter)
FL S
Value of the lower frequency (for
high-pass filter)
FL_SZ
Data file size in bytes
FO S
Filter order
FS S
Sampling frequency
G
The filtered signal
H
Filter coefficients
HLBFLT
Name of Hilbert filter array of
coefficients
HMIN_D
Delay value corresponding to the
minimum in the histogram of
interchannel delay
HSTENP
Name of envelope histogram array
HSTMAX
Maximum value of histogram
HSTSLOP
Name of histogram slope array
i
Dummy variable
ich_dly
Interchannel event delay
ICH_TH
Interchannel event delay threshold
i_dur
Index of event duration
i_n
Index for the noise data array
i_p
Index for the primary data array
i_strt
Index of event start (equals the
start of event start in number of
points)
j
The square root of (-1)
K S
Number of nearest neighbors
mxlc
Location of the maximum
mxlc_r
Location of the maximum of
correlation
mxlc_h
Location of the maximum of
coherence
MU S
The adaptation parameter
N_EV
Total number of events in the whole
the recording
nf
The filter noise data element
N_MIC
Number of microphones
n_rt
Number of related events
nxcr_mx
Maximum of normalized cross
correlation
OVLAP S
Number of overlap points
P
Primary input channel data array
REC_RUR
The recording duration
rt_strt
Related event start time, in
seconds
rt_pp
Peak to peak amplitude of related
event, in volts
sdev
Deviation of event spectral
morphology from that of known
vascular sounds
SMOARR
Name of smoothed envelop array
spcg
Event spacing
SPCG_TH S
Event spacing threshold for pasting
events
STR_ELE
Name of structuring elements array
SUBJ_CLASS_RATIO
Ratio of subject/class distance
SUPARR
Name of supplementary array
tr1, tr2, tr3
Start time of related events in
other channels
td1, td2, td3
Start time of detected events in
other channels
t_c
Start time of current event
t_dur
Event duration, in seconds
t_dur_n
Duration of the newer event, in
seconds
t_strt
Event start time, in seconds
t_strt_n
Start time of newer event, in
seconds
tn_amp
Amplitude of the nearest event
tn_dur
Duration of the nearest events, in
seconds
tn_strt
Start time of near events, in
seconds
td
Start time of detected events
tr
Start time of the related events
x
A complex signal
TABLE 2
Settings
DEFAULT
NAME
DESCRIPTION
VALUE
RANGE
AMP S
Amplitude of
0
0-2
structuring elements
AUT_TH s
Turning the auto
0
0,1 (off,
threshold on and off
on)
DmaxG S
Maximum GAP event
3 S
3-5s
duration
DmaxV S
Maximum vascular
70 ms
event duration
DminG S
Minimum GAP event
2 ms
2-5 ms
duration
DminV S
Minimum vascular
20 ms
event duration
DT_LN S
Length of envelope
1024
A power
data processing array
of 2
DLY_TH S
Threshold of
ICDL_L
max mic
environmental sound
spcg / C
delay
air
ENP_PRE S
The preset value of
30 Mv
25-100 Mv
envelop threshold
ENP_SMT S
Smooth envelope
0
0,1 (no,
control
yes)
FH S
Low pass frequency
1800 Hz
FL S
High pass frequency
70 Hz
FLTR_B S
Band pass filter
1
0,1 (no,
control
yes)
FmaxG S
Maximum GAP event
1500 Hz
800-1800
frequency
Hz
FmaxV S
Maximum vascular
100 Hz
30-120
event frequency
Hz
FminG S
Minimum GAP event
20 Hz
10-70
frequency
Hz
FminV S
Minimum vascular
30 Hz
5-30 Hz
event frequency
FOs
Filter order
3
1-50
FS S
Sampling frequency
4096 Hz
2048 and
up
ICDL_H S
Upper limit of
30 ms
function
interchannel delay
of C in
abd.
ICDL_L S
lower limit of
0 ms
function
interchannel delay
of C in
air
K S
Number of nearest
4 or
Number of
neighbors
more
subjects/
3
OVLAP S
Data overlap length
14
5-
(DT_LN S
/2)
MU S
Adaptation parameter
5
0.01 - 10
N_ENP S
Number of envelope
DT_PTS
1-DT_PTS
data points
N_HST S
Number of points of
4094
2 12 for
envelope histogram
12-bit
N_SMTH S
Number of points for
10
3-20
data smoothing
N_STR S
Number of structuring
5
3-15
elements
RL_TH S
Threshold on related
0.5
0.1-0.9
events
SPCG_TH S
Event spacing
30 ms
5-30 ms
threshold for pasting
SP_TH S
Threshold of the
0.5
0.1-0.9
spectral deviation
TYP S
Type of structuring
0
0,1
elements
In addition, the sounds may be fed into the multichannel tape recorder in a step 206 which may then also feed the sounds to the analog amplifier filter 204 . The amplifier filters and then feeds sounds to an analog to digital converter in the step 208 which converts the sounds to digitized sound signals for analysis by the computer in a step 210 .
As shown in FIG. 8, the computer is able to find acoustic events in a step 212 and to characterize the acoustic events in the step 214 . It recognizes gastrointestinal acoustic phenomena (GAP) events in a step 216 . In addition, from other portions of the routine other patient acoustic characteristics such as trans-abdominal spectra and velocity modulation are determined in a step 220 . Clinical information may also be input through a keyboard or other appropriate means in a step 222 , all of which are fed to a pattern recognition algorithm in a step 224 for providing diagnoses with probabilities in a step 226 . In addition, the information received by the pattern recognition algorithm may be output in a step 228 and subject to physician interpretation in a step 230 .
In an alternative version as shown in FIG. 9, the patient may be attached to a microphone array in a step 240 . The microphone array captures sounds in a step 242 and provides electrical signals to a single or multichannel analog tape recorder in a step 244 and also to an analog amplifier and filter in a step 246 . The sounds are converted from analog form to digital form in a step 248 and the digitized sound signals may be provided to a modem in a step 250 for transmission to a centralized computer facility.
In an ambulatory monitoring system the patient may be connected to the microphone array in a step 262 as shown in FIG. 10 . The microphone captures sounds in a step 264 and the sound signals are recorded by a single channel analog tape recorder in a step 266 for provision to other systems. The patient or the system may supply timing markers indicative of symptoms, events or time duration in a step 268 . The same monitoring schema may also be used for long term monitoring over extended periods of time at low tape speed. In that case the electronic marker signal would comprise a timing signal impressed upon one of the channels. The timing signal would be used by digital processing to remove or reduce timing perturbations introduced by low speed flutter and wow in the tape recorder.
In a still further alternative, as shown in FIG. 11, the patient may be connected to a microphone belt or pad in a step 270 . The microphone belt or pad may convert the sound signals to analog signals in a step 272 and the analog sound signals are recorded in a step 274 for later provision to a computer. The patient or the system may supply timing markers indicative of symptoms, events or time duration in a step 276 .
In general, as shown in FIG. 12, in order to find acoustic events and features in a step 300 the amplitude envelope is calculated for each of the sound channels. An amplitude threshold is then determined in a step 302 for each channel. In a step 304 the events in each channel are determined using the channel amplitude threshold by using the thresholding as a filtering or screening tool. In a step 306 neighboring signals are designated on the same channel signals as a single event. In a step 308 correlated and nearby events are determined in other channels. In a step 310 a determination is made whether the nearest event is part of an actually related event or is merely coincidental. In a step 312 related events are labeled in other channels to avoid double event counting and the nearest events that are part of related events are also labeled following which the return is exited in a step 314 .
The step 300 , involving the calculation of the amplitude envelope, is shown in further detail in FIGS. 14A through B. A data file stores the digitized sound signals and the file size is read in a step 320 . The number of data points in the file is determined to be equal to the file size divided by 2 in a step 322 . The length of the data processing array is then read from a variable indicator in a step 324 and an overlap length previously set is read in a step 326 . The number of data points to be read from the file is calculated to be equal to the data processing array length minus two times the overlap length in a step 328 . The first two times overlap length of data points in the processing array are packed with zeros in step 330 and the counter is set equal to zero in a step 332 . A determination is made if the envelope smoothing flag is on in a step 334 , and if it is, structuring elements are calculated in a step 336 .
Referring now to FIG. 15, the number of structuring elements is read in a step 340 and the amplitude of the structuring elements is read in a step 342 . The type of the structuring elements previously determined is read in a step 344 and a type test is made in a step 346 . If the structuring elements are of type 1 they are calculated according to structuring element equal to the amplitude times the size of the quantity i times π over number of structuring elements minus 1 taken from i=zero to the number of structuring elements in a step 348 . If the type from 346 has been set equal to zero, the structuring element is packed with zeros in each of the elements of the array in a step 350 and the routine is exited in a step 352 to transfer control to a step 354 as shown in FIG. 14A to calculate the filter coefficients.
The filter coefficients are calculated in a routine as shown in FIG. 16 where the frequency domain filter coefficients are calculated in a step 370 .
Step 370 is carried out as shown in FIG. 17 in a step 372 where the Hilbert filter coefficient zero is set equal to one and Hilbert filter coefficients one through half the data length minus 1 are set equal to two in a step 374 . The next coefficient is set to one in a step 376 . The last Hilbert filter coefficients are set equal to zero in a step 378 and return to step 380 to a step 382 shown in FIG. 16 . The request of band pass filtering is tested in 382 and if found to be true, the frequency domain band pass filter coefficients are calculated in a step 384 . In a step 386 each of the Hilbert filter coefficients is multiplied by a corresponding band pass filter coefficient to form a final filter coefficient following which the routine is exited in a step 388 to the prior routine.
The step 384 is carried out in FIG. 18 wherein a step 400 the sampling frequency, high pass frequency and low pass frequencies previously preset to 4096, 70 and 1800 Hz, respectively, are read. The size of the band pass filter coefficient is determined in a step 402 and normalizing occurs in a step 404 . In steps 406 to 412 the band pass filter coefficients are computed and the routine is exited in a step 414 back to step 386 in the filter coefficient calculation routine shown in FIG. 16 .
Referring now to FIG. 14A, the data points are read from the file and placed at the end of the processing array in a step 430 . The counter is incremented in a step 432 and an end of file test is done in a step 434 . If the file processing is ended, the routine is exited in a step 436 . If not, a Fourier transform is calculated in a step 438 following which the transformed frequency domain function is multiplied by filter coefficients in a step 440 , as shown in FIG. 14 B. The inverse Fourier transform is taken in a step 442 to convert back to the time domain and the instantaneous amplitude of the complex signal is taken by taking the square root of the sum of the squares of the real and imaginary portions of the signal in a step 444 . The signal envelope is set equal to the instantaneous amplitude in step 446 and a test is made in a step 448 .
If the test is positive the envelope is smoothed using dilation in a step 450 as may be seen in further detail in FIG. 19 wherein the number of data points of the envelope is read in a step 460 . The size of the structuring element is read in step 462 . The amplitude of the structuring element is read in step 464 and a variable dn is set equal to the structuring element length less one, the whole quantity divided by two in a step 466 . That quantity is assigned to a counter in a step 468 and the counter is incremented in a step 470 . A test is then made to determine whether the number of points is between the original dn number from step 464 or the current counter number in a step 472 . If it is not, the step is returned from in a step 474 . If it is, a supplementary array is loaded in a step 476 . The supplementary array is updated in a step 478 and the i th element of the array is determined in a step 480 following which the routine loops back to the counter in step 470 .
In the event that the envelope is not to be smoothed or the step 450 is completed as shown in FIG. 14B, the last two times the overlap length of data points of processing data array is copied into the beginning of the array in a step 500 . A test is made to determine whether the counter is equal to one in a step 502 . If it is, a number of the data envelope points, equal to the read data points minus the overlap length, starting at two times the overlap length is written to an output file in a step 501 . In the event that the counter is not equal to one the points are written to the output file from the envelope data array starting at envelope element overlap in a step 506 , following which the control is transferred back to step 430 .
In order to perform the amplitude threshold determining step for each channel, step 302 shown in FIG. 12, an amplitude threshold routine is provided as set forth in FIG. 20 . In a step 520 a test is made to determine whether the amplitude threshold has previously been set. If it has, the end position is set equal to the preset in a step 522 , following which the routine is exited in a step 524 . If it has not, the envelope data is read in a step 526 and a histogram of the envelope data is constructed in a step 528 , as shown in greater detail in FIG. 21. A smoothing moving average filter is applied to the histogram data in the step 530 and the peak on histogram and corresponding envelope value are determined in the step 532 . The average slope of the histogram over data segments of preselected length is determined in a step 534 which is shown in greater detail in FIG. 22, wherein in a step 540 the first envelope value is determined. In a step 542 the slope is set equal to the current envelope value minus the next envelope value. An end of data test is made in a step 544 . If the end of data has not been reached, the next envelope value is considered in a step 546 following which control is returned to step 542 . If it has not, a moving average filter is applied in a step 548 to smooth the slope, following which the routine is exited in a step 550 , returning control to a step 552 shown in FIG. 20 . When the histogram slope values are scanned starting at the histogram peak and moving in the direction of increasing envelope values to find an envelope value where the slope first becomes positive. Upon finding the value when the slope first becomes positive, the amplitude threshold value is set equal to that value in a step 556 and the routine is exited in step 524 .
In order to calculate the histogram of the step 528 , as shown in FIG. 21, all elements of the histogram array are set equal to zero in a step 570 . The ADD range previously set is read in a step 572 and the first envelope value is considered in step 574 . Variable i is set equal to the current envelope value times the quantity 4,096 divided by the analog to digital converter range in a step 576 and in a step 578 the i th element of the histogram vector is increased by one step to the next point. An end of data test is made in a step 580 . If the end of data has been reached the routine is exited in return step 582 . If not, control is transferred to a step 584 causing the next envelope value to be considered and then transferring control back to step 576 .
After the amplitude threshold for each channel has been found in step 302 , events in each channel must be located using the channel amplitude threshold in the step 304 . This is carried out in the routine shown in FIG. 23 wherein in a step 600 the amplitude threshold value previously calculated is read as is a preset sampling frequency. The variable i_strt is set equal to zero in step 604 ; and the variable i_dur is set equal to zero in step 606 . First point of the digital envelope data is read in a step 608 and the i_strt value is incremented in a step 610 following which an end of file determination is made in a step 612 . If the end of file has been reached control is transferred to a step 614 . If it has not, the envelope value is tested for whether it is greater than the amplitude threshold; in other words, is there a real reading or a noise reading in a step 616 . If it is not, control is transferred to a test to determine whether i_dur is greater than zero in a step 618 . If i_dur is not greater than zero, control is transferred back to step 608 , causing the next data point to be read. If i_dur is greater than zero, the event number of points is set equal to i_dur in the step 620 . The event duration is set equal to the event number of points divided by the sampling frequency in the step 622 and the event duration is saved to disk in a step 624 following which step 606 is executed.
If the event value is greater than the great amplitude threshold, control is transferred from step 616 to a step 626 causing the duration variable to be incremented. A test is made to determine whether the duration value variable is equal to one in a step 628 . If it is not, control is transferred back to step 608 . If it is, the starting point of the event is set equal to i_start in a step 630 . The event start time is set equal to i_start divided by the sampling frequency in a step 632 . The event start time is then saved to disk in a step 634 following which the next point of the digital envelope data is read in a step 608 .
In order to perform Step 306 where neighboring signals, which are neighboring in time are designated on the same channel signals as belonging to a single gastrointestinal acoustic phenomenon or event, as is shown in FIG. 24 the signals from the first channel are accessed in a step 640 . The first event, which has been previously identified, is accessed in a step 642 . The current event occurrence time and duration previously determined are accessed in a step 644 and the second event in the channel is accessed in a step 646 . The current event occurrence time and durations for the second event are accessed in a step 648 and the event spacing spcg is calculated in a step 650 . In a step 652 if the calculated event spacing is less than a threshold event spacing, control is transferred to a step 654 and the event occurrence time and duration are saved in a step 654 and the second event's occurrence time and duration are stored as the event occurrence and duration in a step 656 following which in a step 658 the next event is considered. In the event that the spacing is less than the threshold, in a step 660 a new duration is calculated as the sum of the spacing, the second event duration and the original duration, and the next event is then considered in a step 658 . Following step 658 a test is made to determine whether any more events are present. If they are not, in step 662 control is transferred to a step 664 , causing the next channel to be analyzed as set forth in the previous steps. A test is then made in a step 666 to determine whether any additional channels need to be analyzed. If there are no more channels to be analyzed, the routine is exited in a step 668 . If there are more channels to be analyzed, control is transferred back to step 642 .
In order to find correlated in nearby gastroacoustical phenomenon or events in other channels as set forth in step 308 shown in FIG. 12, the steps shown in FIG. 25 are performed.
The first channel is taken under consideration in the step 670 and in a step 672 , the first event is to be examined. In a step 674 the current event start time and its duration are read and in a step 676 the event time series is read. In addition, in a step 678 the interchannel event delay threshold, which is determined as set forth in FIG. 26, is read. In a step 680 the search region on other channels is set as well as the search duration which is dependent upon the interchannel event delay threshold. In a step 682 the maximum normalized cross-correlation coefficient and maximum coherence between the events and the sliding window in the search region and in other channels for use in determining the location of maximum on each channel is calculated. In the event that the maximum normalized cross correlation coefficient exceeds a threshold on related events previously set in a step 683 , control is transferred in a step 684 to a step 686 , causing a holding variable to be located with the location of the maximum. In the event the test in the step 684 is negative, control is transferred directly to a step 688 , causing a test to be made to determine whether the maximum coherence between the event and the sliding window in the search region is greater than a threshold on related events. If it is, the second local maximum location is loaded in step 692 . If it is not, control is transferred to a step 690 , causing nearby events to be found and their start times to be saved, as set forth in FIG. 27 and described hereinafter. Control is then transferred to a step 700 where the next event is accessed and processed. A test is made in a step 702 for end of file. if end of file has not been reached, control is transferred back to step 674 . If the end of file for that channel has been reached, control is transferred to a step 704 , causing the next channel to be incremented to and a test is made in a step 706 to determine whether any more channel information is available. If it is, control is transferred back to step 672 for further processing. if it is not, control is transferred to a step 708 , following which the routine is exited and control is transferred back to step 310 to determine whether the nearest event is part of a related event.
Referring now to FIG. 26, the steps for determining the interchannel event delay threshold, which has been previously applied or set forth therein, in a step 710 the event start time for each of the channels is loaded separately and then consideration is shifted to the first channel in a step 712 . The first event is accessed in a step 714 and current event start time is read in a step 716 . Starting at the current event start time a search is made along each of the other channels for the first event to occur and their individual start times are determined. Interchannel delays are calculated as being the difference between each of the other channel start times and the current event start time in a step 720 . In a step 722 indexing is done to the next event and a test is made in a step 724 to determine whether any more events are present on that channel. If they are not, control is transferred to a step 726 where indexing is done to the next channel, and a test is made in a step 728 to determine whether any more channels of data are available. If there are more channels of the data, control is transferred back to step 714 . If there are no more channels of data to be processed, a histogram of the interchannel delay is generated in a step 730 . The histogram is smoothed, with a smoothing average filter in a step 732 and a delay value corresponding to the histogram minimum for delay ranging between preset high and low values is determined in a step 734 . The delayed threshold is then set equal to the delay value in a step 736 and routine is exited in a step 738 .
In order to find nearby events and save their start times and their amplitudes as required in step 690 appearing on FIG. 25, the process set forth in FIG. 27 is employed. In a step 740 the interchannel delay threshold previously determined, the current event channel, the start time and the duration are all read. The first channel is considered in the step 742 and in a step 746 other channels starting at the starting time for the first event are searched and the events' start time, duration and amplitude are found. The interchannel delay is then calculated in a step 748 as being the difference between the initial start time and the first event start time. A test is made in a step 750 to determine whether the interchannel delay is less than the interchannel delay threshold. If it is, control is transferred to a step 752 in which a test is made to determine whether the current event duration is greater than the first event duration on the other channel. If the current event duration is greater than the first event duration on the other channel, control is transferred to a step 754 , causing the start time of the first event on the other channel and its amplitude to be saved. If the responses to step 750 and 752 are either in the negative, control is transferred to a step 756 causing the next channel to be accessed and processed. Control is then transferred to a step 758 , checking for additional channels to be processed. If there are no more channels the routine is exited in a step 760 . If there are more channels to be processed, control is transferred back to the step 746 .
In order to perform the step 310 in which a check is made to determine if the nearest event is part of a related event, the routine set forth in FIG. 28 is carried out. In a step 762 the event start time for each channel is loaded and the first channel is considered in a step 764 . The first event in the current channel is accessed in a step 766 and the current event start time and its duration are read. Related event start times are also read, all in a step 768 . The end time for the related events is calculated as a different between the related event start times and the current event start time. Beginning at the current event start time, each of the remaining channels is searched for the first events to occur other than related events and their start times and durations are determined. The end time of the nearest detected event is determined in a step 774 and the event overlap on channels is checked in a step 776 as set forth in further detail in FIG. 29 . The next event is considered in a step 778 and a test is made in a step 780 to determine whether there are more events. If there are more events, control is transferred back to step 768 . If there are not, the next channel is accessed in step 782 . An end of channel test is made in a step 784 . If the end of channel's test indicates further channels are to be processed, control is transferred to a step 766 . If not, the routine is exited in a step 786 .
The step 776 is performed as set forth in FIG. 29 . The first channel is considered in a step 788 and the start time and end time of the related events as well as the start time and end time of the detected event are obtained in step 790 from storage. A test is made in a step 792 to determine whether the start time of the related event is greater than the start time of the detected event and whether the start time of the related event is less than the end time of the detected event. If it is, control is transferred to a step 794 , causing the events to be labeled as overlapped. If it is not, control is transferred to a step 796 wherein the end time of the related event is tested to determine whether it is greater than the start time of the detected event together with the end time of the related event being tested to determine whether it is less than the end time of the detected event. If both of those equalities are true, control is transferred to step 794 and the events are labeled as overlapped. If not, control is transferred to step 798 wherein a test is made to determine whether the start time of the related event is less than the start time of the detected event and the end time of the related event is greater than the end time of the detected event. If true, the events are labeled as overlap in step 794 . If not, control is transferred to step 800 and the events are labeled as not overlapped, following which in a step 802 , the next channel is considered. A test is made in a step 804 to determine whether any more channels are to be examined. If they are to be examined, control is transferred back to step 790 . If they are not, the routine is exited in a step 806 .
In addition, it is important to characterize the events once they have been identified as set forth in FIG. 13, in a step 810 a test is made to localize each event followed by which in a step 812 event features are combined, including a start time, duration, amplitude, location, spectrum, morphological characteristics, including attack and delay characteristic, and a transmission transfer function followed by exiting the routine in a step 814 .
In order to localize each event, the steps set forth in FIG. 30 are carried out.
In order to perform the step 810 as shown in FIG. 30, the regions of origin are defined in the step 816 , which is shown in more detail in FIG. 31 . The first channel is then considered in a step 818 and the first event on the first channel is accessed in a step 820 . The event start time and peak to peak amplitude are read and the number of related events and the time delay of the related events and the peak to peak amplitudes is also read. If the number of related events is equal to zero as tested for in step 824 , the event location is assigned to the microphone corresponding to the current channel in step 826 and the event has been localized. In the event that the number of the related events is not equal to zero, the origin of the sound region is determined in a step 828 as is more fully set forth in FIG. 32 .
A test is made in a step 830 to determine whether the number of related events is greater than one. If it is, the sound source location is determined in a step 832 as more fully set forth in FIG. 34 . In addition, an input is received from a step 834 wherein the transabdominal speed of sound and abdominal damping characteristics have been determined as set forth in FIG. 33 . Control is then transferred to the step 836 , causing the next event to be considered. In a step 840 a test is made to determine whether there are any more events. If there are more events, control is transferred back to the step 822 . If not, the next channel is considered in a step 842 . A test is made in a step 834 to determine whether all channels have been processed. If they have not, the channel is incremented and control is transferred back to the step 820 . If they have, the routine is exited in a step 846 .
In order to define the regions of origin in step 816 , the number of microphones and their positions are read in a step 850 as shown in FIG. 31. A midline is determined for each microphone pair in a step 852 and in a step 854 the middle point for each microphone triplet is determined. In a step 856 , the abdominal regions are determined, including the border regions, and in a step 858 the order of arrival corresponding to each region, including equal arrival times, is determined following which the routine is exited in a step 860 .
In order to determine the sound region of origin in step 828 , in a step 862 the event order of arrival is read and the event amplitude on each channel is also read, as shown in FIG. 32 . The order of arrival and amplitude information is compared to those of the predetermined regions of origin in a step 864 . In a step 866 an event is assigned to a region of origin on the basis of the comparison and in a step 870 the routine is exited. In order to determine the average transabdominal speed and the abdominal damping characteristics in step 834 , in a step 872 a tape containing prerecorded pure tones and white noise is played through a tape player in a step 874 . that signal is fed through a filter and preamplifier in a step 876 and is boosted by a power amplifier in a step 878 . A shaker coupled to an accelerometer in steps 880 and 882 provides vibration motion to a patient and a pair of transabdominal microphones in a step 886 pick up the resulting vibrational energy. That energy is recorded as electrical signals in a step 888 in a multichannel recorder and is converted in an analog to digital converter in a step 890 and stored in a computer in step 892 . Transmitted signals and events are found in a step 894 and a time delay is calculated in a step 896 . The time delay is fed in a step 900 to calculate the frequency dependent transabdominal speed of sound and spectral modulation and step 900 also receives the measured distances between the microphones from a step 898 .
In order to determine the sound source location after learning the transabdominal speed and abdominal damping characteristics, in a step 902 as shown in FIG. 34 the difference in travel distances of the events are calculated on the basis of the time delay and the average speed of sound obtained from step 834 . In a step 904 , for each microphone pair a hyperbolic curve is determined that describes the locus of sources that would produce the same difference in the sound travel differences. In a step 906 an intersection point of each of the curve pairs is determined and any points that are located outside the abdominal region are excluded from consideration. In a step 908 the middle location of intersection points is determined by averaging their coordinates. In a step 901 the middle point coordinates are assigned to event location coordinates and the routine is exited in a step 912 .
In order to combine the event features as set forth in step 812 , the sampling frequency is read in step 914 as shown in FIG. 35 . The start of the event time is read from disk as is the event duration in a step 916 . The event time series is then read from disk in a step 918 , and the spectrum of the event and its dominant frequency are determined in a step 920 . The peak to peak amplitudes and root-mean-square amplitudes of the event are calculated in a step 922 . In a step 924 other event features, including the instantaneous frequency, spectrogram, attack and decay characteristics, spatial event damping and the like are determined from the amplitude envelope and spectrum of the event and from analyzing nearby and related interchannel events and calculating a transmission transfer function. The event transmission speed is also determined. These event features are saved in a step 926 and the routine is exited in a step 928 .
Recognition of GAP events is carried out in the routine shown in FIG. 36 . The event dominant frequency and duration are read in a step 930 and a test is made to determine whether the duration is greater than the minimum. If it is, control is transferred to a step 936 to determine whether the duration is less than the maximum. If it is, determinations are made in steps 938 and 940 to determine whether the dominant frequency is within a predetermined frequency range. In the event none of those tests hold true, control is transferred to a step 936 and the event is labeled as of an unknown kind. In the event that the duration of frequency range is within the windowed limitations, the event is labeled as a possible gastroacoustic phenomenon in step 942 . A test is made in a step 944 to determine whether environmental noise, for instance, from the fourth channel, may have masked GAP event and a test is made in a step 946 to recognize vascular events. The routine is then exited in step 948 . In order to perform step 944 to recognize environmental noise or events, the threshold of the interchannel delay for environmental sounds is read in a step 950 , as shown in FIG. 37. A reading is made to determine if nearby or related labeled events were found in other channels and their interchannel delay times are read in step 952 . In a step 954 , a test is made to determine whether such a related or nearby event was detected on all microphones. If it was not, control is transferred to the return step 960 . if it was, a test is made to determine whether the absolute value of the time delays is less than the interchannel delay for environmental sounds. If not, the routine is exited. If it is, the event label is changed to being one of environmental noise in a step 958 .
Vascular events are recognized in step 946 , as set forth in FIG. 38 . In a step 962 , the dominant frequency and duration of the event are read and a test is made to determine whether the duration and the dominant frequency are within window values in steps 964 through 970 . If they are not, control is transferred to the return step 982 . If they are, an event spectrum is calculated in a step 972 and normalized. In a step 976 , a series of data related to a library of vascular sound spectra are fed to a step 974 which receives the event spectrum and calculates the deviation of the event spectrum morphology from that of known vascular sounds. If the deviation is less than a spectral threshold value as tested for in step 978 , the routine is exited. If the deviation is greater than or equal to the spectral threshold, the event is labeled as vascular in step 980 and the event is exited.
The system is also capable of performing pattern recognition and as set forth in FIG. 39, a test is made in a step 984 to determine if the patient or subject is a control or has small bowel obstruction or has ileus, as set forth in greater detail in FIG. 40 . In a step 986 , a test is made to determine whether the variables indicate possible inflammatory conditions with location and severity and in a step 988 , diagnostic or probabilities are calculated and output and the routine is exited in a step 990 .
The step 984 is carried out as shown in FIG. 40 . In a step 992 the total number of events and the recording duration is read. In a step 994 the average event rate based on the previous value is determined and the dominant frequency and duration of all events is read in a step 996 . The median duration for all events is calculated in step 998 , and the median dominant frequency for all of the events is calculated in a step 1000 . A nearest neighbor classifier receives the average event rate median duration and median dominant frequency and operates on values in a step 1004 , as set forth in further detail in FIG. 41 . The routine is then exited in step 1006 .
In order to perform the nearest neighbor classification, the distance in the feature space is calculated between the current subject and prediagnosed subjects in a step 1008 . The nearest preclassified or prediagnosed neighbors are determined in a step 1010 and the current subject class is set to the class of the majority of nearest neighbor preclassified neighbors in a step 1012 . The average distance between a current subject and other members of the same class is determined within the space in a step 1014 and the average distance between the subjects in the same class, excluding the current subject is determined in a step 1016 . The ratio of the subject class distance is then determined in the step 1018 and returned to the step 1020 exiting.
Referring now to FIG. 42, a procedure is generally shown therein which may be executed at the microprocessor for filtering multiple channels when a noise estimate is received from a noise channel. In a step 1021 , multiple channel signals are accessed and the first channel is accessed in a step 1022 . A noise channel signal is accessed in a step 1024 and the channel selected is filtered adaptively in a step 1026 . The next channel in the step 1028 and the test is done in the step 1030 to determine whether any more channels are available. If more channels are available, step 1026 is returned to. If not, the routine is exited.
The step 1026 is shown in further detail in FIG. 43, wherein in a step 1034 the primary input channel data is stored in an array P and the reference noise channel data from step 1024 is stored into an array NR. The filter order which has been preselected is read in a step 1036 and is divided by two in a step 1038 to provide i_p.
In a step 1040 the initial filter weights which were set to zero in step 1042 are inputted as is any update filter weights from step 1024 which may have been affected by an adaptation parameter μ. All are provided to step 1040 where in i_n is determined as the difference between i_p and half of the filter order. The initial filter weights in the updated filter weights, however, are available at step 1040 but are not used in the calculation. In a step 1044 the filtered noise referenced input nf is calculated as the sum of the vector product of the initial or updated filter weights multiplied by the reference noise channel data. An output is calculated in step 1046 related to the difference between the primary input channel data and the reference noise input at that point. In a step 1048 the process is indexed to the next sample and a test is done in a step 1052 to determine whether there are more samples. If there are more samples, the filter weights are updated in a step 1054 on the basis of an adaptation parameter MU, which is doubled and then multiplied by the G output and the noise channel data array. The MU value is preset and the entire quantity is added to the previous filter weights to provide updated filter weights available at step 1040 for calculation of the filtered noise reference input in step 1044 .
The system provided outputs in, among other forms, pseudo three-dimensional plots of acoustic frequency event duration and the number of events. For instance, as shown in FIG. 44, there is a clustering of GAP events with a given duration and dominant frequency. These GAP events were detected from the epigastraeum of a normal subject. It should be appreciated that the epigastraeum can have long duration events. A subject with ileus had a relatively small number of events and did not have long duration low frequency events as is shown in FIG. 45 . GAP events collected from the right lower quadrant of a patient with small bowel obstruction showed a generally downward shifting of dominant frequencies plus very low frequency events in the near right hand corner of the plot as shown in FIG. 44 . Tehse were not seen in normal patients or patients having ileus, as shown in FIG. 46 .
In FIG. 47, a pseudo three-dimensional plot is shown of events from the right lower quadrant of a normal subject. The events are characterized by the absence of long duration and low frequency events. In FIG. 48 events taken from the left lower quadrant of a normal subject are similar in characteristic to those shown in FIG. 47 . In FIG. 49 a spectrogram is shown of four events from a normal subject. The events are short and have a dominant frequency at about 500 Hz. In FIG. 50 a spectrogram is shown of a subject with small bowel obstruction which is characterized by long event duration and lowering of the dominant frequencies.
The bowel sound computerized analysis was performed in the diagnosis of human mechanical small bowel obstruction (SBO) after preliminary studies suggested diagnostic gastrointestinal acoustic phenomena (GAP) changes in a rat SBO model.
Fifty-three 20-minute GAP recordings were performed in 43 human subjects [37±18 (mean±SEM) years of age, range 2-94] using a four-microphone array. Recordings were digitized, and each GAP event analyzed for spectrum and duration. Follow-up was obtained on all patients, who were assigned to 1 of 5 categories: proven SBO by laparotomy or contrast radiography (5); suspected but unproved SBO (3); suspected but unproved ileus (3); definite ileus (7); and normal fasted controls (25).
The 8 proven and suspected SBO patients had similar findings, demonstrating major consistent differences from the 10 proven and suspected ileus subjects, and both these groups had significant differences from normal controls.
SBO
Ileus
Control
Significant (p < .05)
n
8
10
25
yes
yes
yes
Number
50
5
25
yes
yes
yes
Events/min
(29-60)
(1.6-10)
(7-46)
Frequency
210
235
325
no
yes
yes
(in Hz)
(192-
(213-
(248-
285)
280)
454)
Duration
34
34
31
no
no
no
(in ms)
(32-35)
(32-35)
(30-33)
Values are median (25th-75th%). p values are for SBO- Ileus (S-I), SBO-Control (S-C), and Ileus-Control (I-C).
Beyond the median data, every obstructed patient but no non-obstructed subject demonstrated intermittent very long duration (1054±188 ms) and low frequency (168±62 Hz) events (>0.0001). Computerized bowel sound analysis may provide a noninvasive method to rapidly and safely diagnose mechanical bowel obstruction and differentiate it from ileus.
The auscultory finding of “high pitched rushes” with SBO may in fact be “low pitched rushes.”
While there has been illustrated and described a particular embodiment of the present invention, it will be appreciated that numerous changes and modifications will occur to those skilled in the art, and it is intended in the appended claims to cover all those changes and modifications which fall within the true spirit and scope of the present invention. | A method and apparatus for characterizing gastrointestinal sounds includes a microphone array to be positioned on a body for producing gastrointestinal sound signals. The signals are digitized and their spectra and duration is determined by a processor. A characterization as to the state of the gastrointestinal tract is made on the basis of the spectra and duration of the sound or event. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to devices for disposing a blade (i.e., blade holder) near a device for transporting a continuous web of material, such as a roll or a drying cylinder of a paper machine, wherein the blade is held in a blade clamping device which can be brought to a position transverse to a direction of movement of the continuous material. In particular, the invention relates to such a device wherein a blade clamping device is disposed on a blade supporting beam, extending transversely to the direction of movement of the web, and a supporting element is coupled with a first drag bearing on a stand and with a second drag bearing on the blade supporting beam.
2. Description of Related Technology
A blade disposed near a continuous web transport device may be used, for example, for the coating of a paper web with a coating composition wherein the blade is utilized to produce a layer of coating having a thickness which is as uniform as possible. Another possible application is the use in the production of crepe paper in which a continuous material runs onto a doctor arranged on a transport roll in order to produce the structure which is typical for crepe paper. In both applications, the paper quality is influenced by the pressing pressure of the blade on the continuous web of material or on the transport device as well as by the size of the working angle of the blade.
Therefore, in order to produce a good working result, it is necessary to be able to bring a blade into a predetermined position with respect to a transport device as precisely possible. However, blades wear and therefore, after they reach their wear limit, they must be replaced or reground. In order to carry out such maintenance, the blade is usually removed from it working position at the roll. In order to be able to produce uniform high quality paper products, it is necessary that the blade of the doctor or scraper be brought exactly to the previously occupied working position. Similarly, blades should be displaceable in their working position, for example, in order to optimize paper quality or in order to reset the paper machine to another type of paper. However, it has been difficult to adjust predetermined blade positions with good repeatable accuracy. Thus, blade holders have been utilized to provide such adjustments.
A blade holder disclosed in EP Patent 0 137 837 shows the arrangement of a blade of a doctor achieved through two rotary movements of a blade supporting beam around a swiveling or rotating axis which is perpendicular to a direction of transport of a web of material through the device. In order to change the position of the blade on the roll, the blade holder has two actuating drives with threaded drives that can be coupled to one another with a coupling and a bevel gear pair. With such a blade holder (which is structurally relatively expensive), although the pressing pressure and the working angle of the blade can be varied independently of one another, it is an unsatisfactory aspect that, after changing or grinding of the blade, for which purpose the blade supporting beam is swung away from the roll, the working angle of the blade must be adjusted again in a relatively complicated way, i.e., "manually", when the new or reground blade is brought to the roll. In order to avoid impairment of quality, this must be done very accurately. However, precise adjustment of this angle is time-consuming and therefore costly.
SUMMARY OF THE INVENTION
It is an object of the invention to overcome one or more of the problems described above. It is also an object of the invention to provide a blade holder wherein it is possible to adjust the working angle of the blade to the transport device with good repeatability after the blade has been swiveled away from the transport device. It is also an object of the invention to provide a blade holder wherein the positioning of the blade occurs more simply and more rapidly than in the blade holders of the prior art. According to another aspect of the invention, it should also be possible to change the working angle of the blade without influencing the pressing pressure of the blade.
According to the invention, a blade holder for disposing a blade near a roll for transporting a continuous web of material includes a blade positioned transversely to a direction of movement of a continuous web of material and mounted on a blade supporting beam, also extending transversely to the direction of movement of the web. The blade supporting beam is swivelable and oscillatable transversely to the direction of movement of the web. The holder includes a supporting element and a stand having a bracket upon which a first drag bearing is disposed. The supporting element is rotatably supported by the first drag bearing. A second drag bearing links the supporting element, the blade supporting beam, and a lever. The holder further includes a device for swiveling the blade supporting beam from a working position to a maintenance position, whereby when in the maintenance position, the blade supporting beam holds the blade at a larger distance from the web transport roll than when in the working position. The swiveling device is linked to the lever at a first linking point and the swiveling device is linked to the supporting element at a second linking point. Changing the distance between the first linking point and the second linking point swivels the blade supporting beam. The blade holder further includes a positioning device for adjusting a blade working angle. The positioning device is linked to the stand at a third linking point and linked to the supporting element at a fourth linking point. Positioning of the blade is achieved by changing the distance between the third linking point and the fourth linking point.
Other objects and advantages of the invention will be apparent to those skilled in the art from the following detailed description taken in conjunction with the drawings and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partially schematic side view of a device according to the invention shown with a web transport roll and in a first position.
FIG. 2 is a partially schematic side view of the device of FIG. 1 shown in a second position.
FIG. 3 is a partially schematic side view of the device of FIGS. 1 and 2 shown in a third position.
FIG. 4 is a schematic view of the device of FIG. 1 shown coupled to a second device according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
According to the invention, a blade holder includes a supporting element linked to a drag bearing on a lever in such a way that the blade holder is provided with a swiveling device connected to the lever and the supporting element, with the aid of which the blade supporting beam can be swiveled from a working position into a maintenance position, which is at a larger distance to the roll, whereby the swiveling movement is achieved by changing the distance between the linking point of the swiveling device on the lever and on the supporting element. Furthermore, a blade holder according to the invention is provided with a positioning device connected to the stand and the supporting element in order to adjust the working angle of the blade, whereby the positioning of the blade is done by changing the distance of the two linking points of the positioning device on the stand and on the supporting element.
In order to increase the distance of the blade supporting beam from the transport device, which distance can also be zero, the distance of the linking point on the lever and on the supporting element is increased by a certain amount. This can be achieved in a preferred embodiment of a blade holder of according to the invention by having a cylinder in the swiveling device operated with a pressure medium, for example, a pneumatic cylinder. After the maintenance work on the blade was completed, the distance between the two linking points is reduced again to the original value. Thus, in order to change from the working position into the maintenance position, and back again into the working position, only a translation movement of the same length needs to be performed. Based on the cooperation of the components of the invention, which will be explained in more detail herein, after these two movements, the blade has the same blade working angle as before. A blade holder according to the invention is thus characterized by simple operation. On the other hand, such translation movements can be performed relatively rapidly and also very accurately, for example, with the pneumatic cylinder already mentioned herein.
In a preferred embodiment of the invention, the tip of the blade can be disposed in a rotary axis of the first drag bearing. This can be constructed expediently in such a way that the rotary axis of the drag bearing is on a radius on which the blade moves in its movement from the maintenance position into the working position. In such an embodiment, it is possible to vary the working angle by changing the distance between the linking points of the positioning device on the stand and the supporting element, so that, as a result, the pressing pressure of the blade is influenced. This is possible because, when the positioning device is activated, the blade turns around only its tip without the arrangement of the blade with respect to the transport device being altered in any other way.
An alteration of the distance between the linking points of the positioning device can be achieved by preferably providing the positioning device with a threaded drive disposed on a connecting line between the linking points.
In order to achieve a ready operation of the blade holder in an embodiment of the invention the holder includes a control. The blade holder according to the invention can thus be transferred into the maintenance position and working position with appropriate control signals, for example, from a control panel by remote control. Thus, remote-controlled adjustment of the blade working angle can be achieved.
Furthermore, in a preferred embodiment of a blade holder according to the invention, the particular blade working angle can be detectable by a sensor system and emitted as a corresponding electrical signal. By entering these signals into the controller! which correspond to the particular instantaneous blade working angle, an exact adaptation between a target arrangement and actual arrangement of the blade holder can be achieved.
With reference to the drawings, a blade holder according to the invention, shown in FIG. 1, is disposed at an end face of a roll 1 of a paper machine for producing crepe paper. The roll 1 rotates in a clockwise direction. On a second end face of the roll 1 there is a second (mirror image) blade holder according to the invention, which corresponds to that shown in FIG. 1 (see FIG. 4). A blade supporting beam 2 is secured between the two blade holders, perpendicularly to the plane of the illustration, along the surface of the roll 1. Two blade holder B1 and B2 are shown schematically in FIG. 4 connected by the beam 2. As can be seen, in addition, the blade holder has a supporting element 3, a lever 4, (shown in broken form), and a fixed stand 5. The arrangement of these elements is such that, when looking at the representation shown in FIG. 1, the lever 4 is in front of the supporting element 3 and this is again in front of the blade supporting beam 2. A face 6 of the blade supporting beam 2 and a surface 7 of the stand 5 are approximately at the same height.
Starting from a foot part 8, the supporting element 3 has two carrier arms 9 and 10, which are approximately perpendicular to each other. A threaded drive 15 is located between the supporting element 3 and the stand 5 as a positioning device 14. This drive is driven by an electric motor (not shown), and is disposed between a linking point 16 on the stand 5 and a linking point 17 on the first carrier arm 9 of the supporting element 3 along an (imaginary) connecting line 18 between the linking points 16 and 17. The threaded drive 15 is secured so that it can rotate about the two linking points 16 and 17. With the aid of a first drag bearing 20, the supporting element 3 is secured on the stand 5 with its second carrier arm 10 so that it can swivel (see especially FIG. 2).
As can be seen in FIG. 1, the blade supporting beam 2, which is connected rigidly with the lever 4, is supported in a second bearing rotatably and so that it can be shifted axially (not shown here) in the foot part 8 of the supporting element 3. There is a swiveling device 24 between a linking point 22 in the region of the other end of the lever 4 and another linking point 23 on the first carrier arm 9 of the supporting element 3. This linking device! is provided with a pneumatic cylinder 25, the working direction of which runs along a connecting line 26 between the two linking points 22 and 23 of the swiveling device 24. The connecting line 26 is at a greater distance from the drag bearing 21 than that of the connecting line 18. Similarly to the threaded drive 15, the pneumatic cylinder 25 is also secured so that it can rotate around its two linking points 22 and 23.
The stand 5, in which the rotary axis (not shown) of the roll 1 is supported, having a bracket 28 at its lower end. The bracket 28 can be displaced with the aid of a threaded bolt 27. A linking point 16 of the positioning device 14 and the first drag bearing 20 of the supporting element 3 are located on the bracket 28 of the stand 5. By rotating the threaded bolt 27, the distance of the linking point 16 and of the first drag bearing 20 from a peripheral line of the roll 1 can be altered along a displacement axis. "Distance" in this connection is defined as the actual distance line which runs in space in the figures onto the plane of the drawing in FIGS. 1-3.
The blade supporting beam 2, which is a supporting beam of a doctor 30 in the example of the embodiment shown here, is supported in the second drag bearing 21, together with the supporting element 3 and the lever 4. It can perform relative movements with respect to the supporting element 3 around the axis of the second drag bearing 21. The blade supporting beam 2 is secured so that it cannot rotate with respect to the lever 4.
The pressing pressure of the doctor 30 that is located on the blade supporting beam 2 can be varied with a blade-tensioning device, which is known in the state of the art and is not shown here. This is achieved by bending the doctor 30 along its entire length (perpendicularly to the plane of the drawing) so that a bending force is produced in the direction to the roll 1.
Before the first use of the blade holder, the blade holder is located in a maintenance position as shown in FIG. 2. The axis of the first drag bearing 20 is adjusted with the aid of the threaded bolt 27 in such a way that it is located directly above the peripheral line of the roll 1, as shown in FIG. 2. After the doctor 30 is secured on the blade supporting beam 2, and a bending force is applied to it that will cause a predetermined pressing pressure, by activating the swiveling device 24, the blade holder will be arranged in the working position on the roll 1. The sharp edge, or the blade tip which is shown in the figures, of the doctor 30, is thus flush with the rotary axis of the second drag bearing 21. The second blade holder according to the invention, which is located on the other end face of the roll 1 and is not shown here, is always adjusted in the same way as the blade holder which is shown. In order to swivel the blade supporting beam 2, the two blade holders always perform the same movements synchronously.
In order to adjust the blade working angle, that is, the angle formed by a tangent to the roll 1 by the blade tip together with the blade, the stand 3 can be swiveled together with the blade supporting beam 2 around the tip of the blade. The positioning device 14 is used for this purpose. For example, if starting from the position shown in FIG. 1, the doctor 30 is to be directed at a blade working angle shown in FIG. 3, the threaded drive 15 of the positioning device 14 is activated in such a way that the distance between the linking points 16 and 17 is increased by an amount that corresponds to the new blade working angle. As a result of this, the supporting element 3 rotates in the counterclockwise direction around the first drag bearing 20. Since the distance between the two linking points 22 and 23 remains the same, the lever follows this movement. Altogether, this causes a rotary movement of blade supporting beam 2, also in the counterclockwise direction, but around the first drag bearing 20.
As already described herein, the tip of the blade is flush with the axis of the first drag bearing 20. Consequently, the blade supporting beam 2 turns around the tip of the blade, as a result of which the new blade working angle is set up after the movement is completed. During this, there is a functional cooperation between the particular distance of the linking points and the resulting blade working angle. It is clear from the above explanations that the blade working angle can be adjusted continuously, independently of the pressing pressure. This can be done even during the operation of the paper machine, for example, in order to compensate for the wear of the blade tip of the doctor 30. Thus, on the one hand, the blade working angle that was found to be optimum for a certain type of paper can always be adjusted and maintained reproducibly in a simple manner. On the other hand, the blade working angle itself can be optimized during operation in a simple manner without changing the pressing pressure.
Since the doctor 30 is located on an imaginary connecting line of the axes of the two drag bearings 20 and 21, when using the doctor 30, no moments occur around the axis of the second drag bearing 21. Consequently, in spite of the dynamic load on the doctor 30, torsional vibrations can be avoided. Another advantage arises from the fact that the blade tip is flush with the axis of the first drag bearing 20. As a result of this arrangement, it becomes possible to remove the dynamic loads acting on the blade without the creation of moments in the robust stand 5 of the support of the paper machine, which is not shown here.
As it is well-known, such doctors wear during use. Now, after the wear of the doctor 30 has exceeded the permissible tolerance, paper production is interrupted and the pneumatic cylinder 25 of the swiveling device 24 is loaded in the reverse direction. As a result of the translation movement of the cylinder roll 29 of the pneumatic cylinder 25, the distance between the two linking points 22 and 23 is increased by a certain amount. Therefore, the lever 4 performs a swiveling movement in the clockwise direction around the axis of the second drag bearing 21. Thus, the blade supporting beam 2, which is non-rotatably connected to the lever 4, also turns in the clockwise direction around the second drag bearing 21. As shown in FIG. 2, this results in an increase of the distance of the doctor 30 from the roll 1.
In this maintenance position of the blade holder, the doctor 30 is accessible from the side and can also be replaced by another doctor. If, based on the state of wear, it is still possible, it is preferable to regrind the doctor 30. However, as a result of this, the width of the doctor 30 is reduced. So that the blade tip can always be brought in the axis of the first drag bearing 20 in spite of the different widths of the doctor, the doctor is supported on its end which is opposite to the blade tip onto a displaceable butting surface, which is not shown. With the stopping strip, the different widths of the doctor 30 can be compensated. When the doctor 30 is again in the intended position, by applying the original pressure of the pneumatic cylinder 25, the distance between the two linking points 22 and 23 can be reduced again to the original value. As a result of this, the lever 4 and the blade supporting beam 2 turn in the counterclockwise direction around the second drag bearing 21, back along the same path into their original position, the working position. As a result, the blade supporting beam is arranged with respect to the roll 1 at the same blade working angle and with the same pressing pressure as before.
In other embodiments of the invention, which are not shown on the figures, one can also provide that the stiffness of the blade holders according to the invention, arranged on one of the faces, can be increased by mechanical transverse connections, for example, with a transverse brace. Similarly, it is also possible to provide manually operated trapezoidal threaded spindles instead of the electric drive of the threaded drive.
The foregoing detailed description is given for clearness of understanding only, and no unnecessary limitations should be understood therefrom, as modifications within the scope of the invention will be apparent to those skilled in the art. | A blade holder for disposing a blade proximate to a roll for transporting a continuous web of material includes a blade positioned transversely to a direction of movement of a continuous web of material. The blade tensioning device is disposed on a blade supporting beam extending transversely to the direction of movement of the web, the blade supporting beam swivelable and oscillatable transversely to the direction of movement of the web. The holder includes a supporting element and a stand having a bracket upon which a first drag bearing is disposed, the supporting element rotatably supported by the first drag bearing. A second drag bearing links the supporting element, the blade supporting beam, and a lever. The holder also includes a swiveling device for swiveling the blade supporting beam from a working position to a maintenance position and a positioning device for adjusting a blade working angle. | 3 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a method and an apparatus for processing stream encryption/decryption by a diffusion mechanism, and more particularly to a diffusion operation for a matrix of at least one dimension including a displacement and an exclusion or (XOR), so that a plurality of diffused starting positions is converted into a diffused function operation for quickly and continuously performing an XOR operation with a plaintext (or ciphertext) stream to generate a ciphertext (or plaintext) stream.
[0003] 2. Description of the Related Art
[0004] Prior art stream encryption/decryption method and apparatus use a random code generator to output a numeric value to a register, and the bits in the register are taken out constantly to perform an XOR with a plaintext stream to generate a ciphertext stream by the operations of linear or non-linear combination function and the shifts of register. Similar process is applied to the ciphertext to obtain the plaintext stream. The key point of safety of the prior art emphasizes on the linear complexity of a combination function so as to produce a large non-correlation with the bitstream taken out from the register and reduce the risk of breaking the combination function.
SUMMARY OF THE INVENTION
[0005] To overcome the issue of stream correlation produced by the prior art, the present invention uses an operation of a diffusion mechanism to represent a position by a linear function, and all position combinations are represented by a diffusion function, so that the maximum recurring period and linear complexity are reflected in the diffusion function to replace the prior art non-linear combination function and random code generator.
[0006] The technical measures taken to overcome the foregoing problem by the present invention are described as follows:
[0007] A diffusion mechanism that needs to repeat the diffused operations of a plurality of diffused starting positions has a fast operating speed in that the hardware design of the diffusion function can simultaneously complete the operations at a time. The diffusing mechanism also has a maximum recurring period and linear complexity for controlling the plurality of diffused starting positions, and the diffusion mechanism comprises the following steps:
[0008] (a) Select a diffused area of at least one dimension.
[0009] (b) The diffused area includes a plurality of diffused starting positions and at least one output position.
[0010] (c) The diffused starting position includes a starting position and an ending position.
[0011] (d) Output a trigger signal, and the trigger signal ∈ {0,1}.
[0012] (e) Execute a diffused operation of at least one dimension sequentially from the starting position to the ending position, and this step is carried out for at least one time; and
[0013] (f) The output position outputs a bit.
[0014] The effects of the present invention are compared with those of the prior art as follows. In prior art stream encryption/decryption method and apparatus, the internal random code generator controls the random codes to produce a maximum recurring period, and the internal non-linear combination function controls each segment of the output streams to produce a minimum correlation. However, if the non-linear combination function is broken, the stream cipher/decipher will become useless.
[0015] In the stream encryption/decryption method and apparatus of the present invention, the diffusion function determines the correlation between the maximum recurring period and the output stream. Unlike the non-linear combination function, the diffusion function is opened to the public, and thus even if the content of the internal register is broken, the present invention can be used again by resetting the content of the register.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 is a schematic view of the hardware layer of a diffusion mechanism according to the present invention; and
[0017] FIG. 2 is a schematic view of the hardware layer of a diffusion module according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0018] The stream encryption/decryption method and apparatus of the present invention uses a diffused operation to form a diffusion mechanism, and at least one combination of the diffusion mechanism forms a diffusion module that comprises:
[0019] A diffused operation, for returning the value of the diffused area to the original value for every period of diffusions, as to the recurring period of diffusion. Therefore, there are two types of diffusion operations: a diffusion operation at a state after diffusion from the start to the end of a cycle, or a diffused operation at a state before diffusion from the end to the start of the diffusion.
[0020] The state after diffusion includes a diffused area, and the diffused area includes a diffused starting position, and an XOR operation is performed for the new value of the diffused starting position with a trigger signal, and the starting position is used as the diffusion center, and the diffusion direction is from the inside to the outside sequentially. The new value produced in the diffused area is an original value performing an XOR operation with the new value at an internal adjacent position until the entire diffused area is completed.
[0021] The state before diffusion includes a diffused area, and the diffused area includes a diffused starting position, and the starting position is used as the diffusion center, and the diffusion direction is from the outside to the inside sequentially. The new value produced in the diffused area is an original value performing an XOR operation with the original value at the internal adjacent position until the entire diffused area is completed, and the new value of the diffused starting position is obtained by performing an XOR operation for the original value with the trigger signal.
[0022] Symbols and Definition of Diffusion:
[0023] S is a diffused area with a m-dimensional matrix comprising a combination of n positions, m>0; n>0, and the position label is shown below:
[0024] For example, (a) one-dimensional S
1 2 3 . . . n-1 n
[0025] (b) Two-dimensional S
1 5 . n-3 2 6 . n-2 3 7 . n-1 4 8 n
[0026] S(i): S uses the position i as the diffused starting position to execute the diffused operation.
S ( i 1 , i 2 , Λ , i k ) i → j : S
S uses {i 1 ,i 2 ,Λ,i k |1≦i k ≦n} sequentially as the diffused starting positions, and the set uses the position i as the starting position and the position j as the ending position to sequentially execute the diffused operation.
[0027] For example,
S ( 1 : n ) i → i - 1 : S ( a )
S uses the positions 1 to n sequentially as the diffused starting positions, and the position i is the starting position, and the position i−1 is the ending position to sequentially execute the diffused operation.
S ( 1 : n ) i → i = [ S ( 1 : n ) i → i - 1 ] ( i ) ( b )
[0028] S t is a diffusion mechanism for executing the operation of
S ( i 1 , i 2 , Λ , i k ) i → j
for t times.
[0029] For example, (a) S t =[S t−1 ] 1 (b) S 2 =[S 1 ] 1 (c) S 0 =S
[0030] S t 1 xt 2 executes the operation of S t 2 for t 1 times.
[0031] For example, (a) S t 1 xt 2 =[S (t 1 −1)xt 2 ] t 2 (b) S 2×2 =[S 1×2 ] 2 =S 4 (c) S 0×2 =S 0 =S
[0032] F is a m+1 dimensional matrix f representing n positions of S.
[0033] F t is a diffusion function for executing the operation of S 1 for t times and the linear function combination of n positions.
[0034] For example, (a) F t =[F t−1 ] 1 (b) F 2 =[F 1 ] 1 (c) F 0 =F
[0035] S t 1 (F t 2 ) is an operation of S t 1 by F t 2 , and n positions produce a new value.
[0036] For example, (a) S 2 =S 1 (F 1 ), (b) S 1 =S(F 1 ), (c) S=S(F), (d) S t =S t 1 xt 2 =S (t i −1)xt 2 (F t 2 )
[0037] T is a m-dimensional zero matrix, indicating that the values of n positions have no inverse phase.
[0038] T t is a trigger area having a trigger signal of 1 for executing the operation of S 1 for t times, and the new value produces a position of a reverse phase.
[0039] For example, (a) T t =T t−1 (F 1 )⊕T 1 (b) T 2 =T 1 (F 1 ) ⊕T 1 (c) T 0 =T (d) T t =T t 1 xt 2 =T (t i −1)xt 2 (F t 2 )⊕T t 2
[0040] The embodiments of a diffusion module are described below.
[0041] To make it easier for our examiner to understand the content of the present invention, the diffused operation, diffusion mechanism, diffusion function, trigger area, software design, and hardware design are described in details as follows:
[0042] Set a one-dimensional diffused area S comprised of 4 positions labeled as 1, 2 , 3 and 4, and
S 1 = S ( 1 : 4 ) 1 → 4 .
[0043] The diffused operation uses 1 as the diffused starting position for the operation as shown in Table 1.
TABLE 1 Diffused Stream S State After Diffusion State Before Diffusion 1 i. 1 = 1 ⊕ Tr i. 4 = 4 ⊕ 3 2 ii. 2 = 2 ⊕ 1 ii. 3 = 3 ⊕ 2 3 iii. 3 = 3 ⊕ 2 iii. 2 = 2 ⊕ 1 4 iv. 4 = 4 ⊕ 3 iv. 1 = 1 ⊕ Tr Tr: trigger signal ⊕: XOR
[0044] Diffusion mechanism:
S 1 = S ( 1 : 4 ) 1 → 4 ,
[0045] and executes the diffused operation at the state before diffusion S 1 . The relation of an operation of a diffused starting position corresponding to a new value produced for each position is shown in Table 2.
TABLE 2 S S = S(1) S = S(2) S = S(3) S = S(4) 1 1 2 1 1 ⊕ 2 ⊕ 3 2 1 ⊕ 2 1 ⊕ 2 2 ⊕ 3 1 ⊕ 2 3 2 ⊕ 3 1 ⊕ 3 1 ⊕ 3 2 ⊕ 4 4 3 ⊕ 4 2 ⊕ 4 1 ⊕ 2 ⊕ 3 ⊕ 4 1 ⊕ 2 ⊕ 3 ⊕ 4 ⊕: XOR
[0046] Diffusion Function: Take F 7 =F for example, the diffused operation at a state before diffusion is used. The diffusion function for six consecutive times is shown in Table 3.
TABLE 3 S F 1 F 2 F 3 F 4 F 5 F 6 1 1 ⊕ 2 ⊕ 3 2 ⊕ 3 ⊕ 4 2 ⊕ 3 1 ⊕ 4 1 1 ⊕ 2 ⊕ 3 ⊕ 4 2 1 ⊕ 2 3 2 ⊕ 4 3 ⊕ 4 1 ⊕ 3 1 ⊕ 3 ⊕ 4 3 2 ⊕ 4 3 ⊕ 4 1 ⊕ 3 1 ⊕ 3 ⊕ 4 2 1 ⊕ 2 4 1 ⊕ 2 ⊕ 3 ⊕ 4 1 1 ⊕ 2 ⊕ 3 2 ⊕ 3 ⊕ 4 2 ⊕ 3 1 ⊕ 4 ⊕: XOR
[0047] Trigger Area: The trigger signal is 0, and the new value of each position as shown by the diffusion function. The trigger signal is 1, and
T 1 = T ( 1 : 4 ) 1 → 4
[0048] repeats executing the diffused operation at the state before diffusion. The new value has a reverse phase as shown in the position labeled as 1 in Table 4.
TABLE 4 S T 1 T 2 T 3 T 4 T 5 T 6 T 7 1 1 1 1 0 0 1 0 2 0 1 0 1 1 1 0 3 1 0 0 0 1 1 0 4 1 0 1 1 1 0 0
[0049] Software Design of Diffusion Module:
[0050] Embodiment I: 16×1 diffusion module of S 1×1 .
[0051] A plaintext is one-dimensional zero matrix.
[0052] A password is a 16-bit one-dimensional zero matrix.
[0053] Initialization:
[0054] 1. The trigger signal is 1.
[0055] 2. The passwords are entered sequentially into the diffused area.
[0056] 3. The output position is the last bit of the diffused area.
[0057] 4. S 1×1 =S 1 outputs once for each operation.
5. S 1 = S ( 1 : 16 ) 13 → 13 .
[0058] Encryption Flow:
[0059] 1. Sequentially obtain a bit from the plaintext stream.
[0060] 2. The diffused area executes the operation of S 1 , and the diffused area produces a new value.
[0061] 3. Perform an XOR for the last bit in the diffused area with a bit of the plaintext stream.
[0062] 4. Repeat the foregoing steps until the plaintext is finished.
[0063] Description:
S 0 [0000000000000000] S 1 [1011001101100011]→Perform XOR for the last bit with a bit of the plaintext stream. S 2 [0110100110110010]→Perform XOR for the last bit with a bit of the plaintext stream. S 2 16 −1 [0000000000000000]→Equal to S 0 . Results: (Take S 1 to S 64 ) 1011011100111011 (S 1 to S 16 ) 0000100100010111 (S 17 to S 32 ) 0100000011010100 (S 33 to S 48 ) 1011011111111110 (S 49 to S 64 )
[0073] Embodiment II: 16×1 diffusion module of S 1×2 .
[0074] A plaintext is a one-dimensional zero matrix.
[0075] A password is a 16-bit one-dimensional matrix.
[0076] Initialization:
[0077] 1. The trigger signal is 1.
[0078] 2. Enter the passwords sequentially into the diffused area.
[0079] 3. The output position is the last bit of the diffused area.
[0080] 4. S 1×2 =S 2 =[S 1 ] 1 , and output once for every two operations.
5. S 1 = S ( 1 : 16 ) 13 → 13 .
[0081] Encryption Flow:
[0082] 1. Take a bit sequentially from the plaintext stream.
[0083] 2. The diffused area executes the operation of S 2 , and the diffused area produces a new value.
[0084] 3. Perform XOR for the last bit of the diffused area with a bit of the plaintext stream.
[0085] 4. Repeat the foregoing steps until the plaintext is finished.
[0086] Description:
S 0 [0000000000000000] S 1×2 [0110100110110010]→Perform XOR for the last bit with a bit of the plaintext stream. S 2×2 [1001111000110101]→Perform XOR for the last bit with a bit of the plaintext stream. S (2 16 −1 )× 2 [0000000000000000]→Equal to S 0 Results: (Take S 1×2 to S 64×2 ) 0111010100010111 (S 1×2 to S 16×2 ) 1000111001111110 (S 17×2 to S 32×2 ) 1000010100011110 (S 33×2 to S 48×2 ) 1101011100000100 (S 49×2 to S 64×2 )
[0096] Embodiment III is a 4×4 diffusion module of S 1×1 .
[0097] A plaintext is a one-dimensional zero matrix.
[0098] A password is a 16-bit two-dimensional zero matrix.
[0099] The initialization and encryption flow are the same as those described in Embodiment I, but the diffusion mechanism is changed to
S 1 = S ( 1 : 16 ) 8 → 8 .
[0100] Description:
S 0 [0000000000000000] S 1 [1010001000100100]→Perform XOR for the last bit with a bit of the plaintext stream. S 2 [1100000110010011 ]→Perform XOR for the last bit with a bit of the plaintext stream. S 2 16 −2 [0000000000000000]→Equal to S 0 .
[0105] Results: (Take S 1 to S 64 )
0111000100100111 (S 1 to S 16 ) 0000001100101011 (S 17 to S 32 ) 1110101001111110 (S 33 to S 48 ) 0011000001101100 (S 49 to S 64 )
[0110] Hardware Design of Diffusion Module:
[0111] The operations of the S t 1 xt 2 diffusion mechanism used for a software design are the operations of the F t 2 diffusion function and the reverse phase of the T t 2 , which are converted into a hardware design, and the synchronous operation of the hardware design obviously can reduce the time of forming streams as shown in FIG. 1 .
[0112] Embodiment I: a 16×1 diffusion module of S 1×2 .
S 1 × 2 = S 2 = [ S ( 1 : 16 ) 13 → 13 ] 1
[0113] is converted into F t 2 =F 2 and the linear function at each position is shown in Table 5.
TABLE 5 f(1) 1 ⊕ 3 ⊕ 5 ⊕ 7 ⊕ 9 ⊕ 13 f(2) 1 ⊕ 2 ⊕ 4 ⊕ 6 ⊕ 7 ⊕ 8 ⊕ 9 ⊕ 10 ⊕ 11 ⊕ 13 ⊕ 14 ⊕ 15 f(3) 1 ⊕ 9 f(4) 1 ⊕ 2 ⊕ 10 ⊕ 13 f(5) 3 ⊕ 5 ⊕ 11 ⊕ 14 ⊕ 15 f(6) 1 ⊕ 2 ⊕ 3 ⊕ 4 ⊕ 5 ⊕ 6 ⊕ 9 ⊕ 12 ⊕ 14 f(7) 9 ⊕ 13 f(8) 1 ⊕ 2 ⊕ 5 ⊕ 10 ⊕ 15 f(9) 2 ⊕ 9 ⊕ 11 ⊕ 13 f(10) 1 ⊕ 2 ⊕ 7 ⊕ 10 ⊕ 12 ⊕ 14 f(11) 1 ⊕ 2 ⊕ 5 ⊕ 9 ⊕ 13 ⊕ 15 f(12) 1 ⊕ 3 ⊕ 5 ⊕ 6 ⊕ 9 ⊕ 10 ⊕ 13 ⊕ 14 ⊕ 15 ⊕ 16 f(13) 3 ⊕ 7 ⊕ 9 ⊕ 11 ⊕ 13 ⊕ 14 ⊕ 15 ⊕ 16 f(14) 1 ⊕ 3 ⊕ 5 ⊕ 7 ⊕ 8 ⊕ 9 ⊕ 10 ⊕ 11 ⊕ 12 ⊕ 15 ⊕ 16 f(15) 3 ⊕ 4 ⊕ 7 ⊕ 8 ⊕ 9 ⊕ 10 ⊕ 11 ⊕ 12 f(16) 2 ⊕ 5 ⊕ 6 ⊕ 8 ⊕ 9 ⊕ 10 ⊕ 11 ⊕ 12 ⊕ 13 ⊕ 15 ⊕ 16
T t 2 =T 2 : 0110100110110010
[0115] Operation Flow:
in=1 T t 1 ×2 =T (t 1 −1)×2 ( F 2 )⊕T 2 , S t 1 ×2 =S (t 1−1)×2 ( F 2 ) ⊕T t 1 ×2
in=0 : S t 1 ×2 =S (t 1 −1)×2 ( F 2 )
[0116] Embodiment II: a 16×1 diffusion module of S 1×1 .
S 1 × 1 = S 1 = S ( 1 : 16 ) 13 → 13
[0117] is converted into F t 2 =F 1 , and the linear function of each position is shown in Table 6.
TABLE 6 f(1) 1 ⊕ 7 ⊕ 9 ⊕ 11 f(2) 1 ⊕ 2 ⊕ 5 ⊕ 8 ⊕ 10 ⊕ 12 f(3) 5 ⊕ 7 ⊕ 9 ⊕ 11 f(4) 1 ⊕ 3 ⊕ 6 ⊕ 7 ⊕ 8 ⊕ 10 ⊕ 12 ⊕ 13 f(5) 1 ⊕ 3 ⊕ 5 ⊕ 9 ⊕ 11 ⊕ 13 f(6) 2 ⊕ 4 ⊕ 5 ⊕ 6 ⊕ 10 ⊕ 12 ⊕ 13 f(7) 1 ⊕ 3 ⊕ 9 ⊕ 11 f(8) 1 ⊕ 2 ⊕ 4 ⊕ 7 ⊕ 9 ⊕ 10 ⊕ 12 ⊕ 13 ⊕ 14 f(9) 3 ⊕ 7 ⊕ 11 ⊕ 13 ⊕ 14 f(10) 1 ⊕ 4 ⊕ 5 ⊕ 8 ⊕ 9 ⊕ 12 ⊕ 14 f(11) 1 ⊕ 3 ⊕ 5 ⊕ 7 ⊕ 9 ⊕ 11 ⊕ 14 f(12) 2 ⊕ 3 ⊕ 4 ⊕ 5 ⊕ 6 ⊕ 7 ⊕ 8 ⊕ 9 ⊕ 10 ⊕ 11 ⊕ 12 ⊕ 13 ⊕ 14 ⊕ 15 f(13) 1 ⊕ 14 ⊕ 15 f(14) 1 ⊕ 2 ⊕ 13 ⊕ 15 f(15) 2 ⊕ 3 ⊕ 14 ⊕ 16 f(16) 3 ⊕ 4 ⊕ 13 ⊕ 15
T t 2 =T 1 : 1011001101100011
[0119] Operation Flow:
in=1 : T t −1 =T t −1 (F 1 ) ⊕T 1 , S t =S t−1 ( F 1 ) ⊕T t
in=0 : S t =S t−1 ( F 1 )
[0120] Embodiment III: a diffusion module of S 1×t 2 combination is shown in FIG. 2 .
A 4 × 4 , S 1 × 1 : S 1 = S ( 8 ) 8 → 8 .
A 16 × 1 , S 1 × 1 : S 1 = S ( 13 ) 13 → 13 .
A 16 × 1 , S 1 × 2 : S 2 = [ S ( 13 ) 13 → 13 ] 1 .
[0121] Operation Flow:
[0122] A pulse controller controls the execution of three diffusion mechanisms by the pulse, and outputs a result of performing an XOR operation for a bit with a bit of the plaintext (or ciphertext) for the completed execution of every three diffusion mechanisms, and the diffusion module is executed repeatedly to produce a ciphertext (or plaintext) stream.
[0123] In the embodiments, the diffusion function can be used independently or expanded simply to one or more combinations, and the operation of the diffusion function is used to output the number of executions at the first bit, which can hardly compute the correlation. Furthermore, the value of a trigger area in each diffusion function for different combinations of the diffusion function cannot be known. Thus, the output value of the next bit cannot be found. In FIG. 2 , a password is inputted from the “in end-point” into an internal register indirectly by the trigger signal method. Even if the content of the register can be guessed, the original password cannot be found, and the cipher still cannot be used. If a force breaking method is used, it is necessary to take 2 n+1 trials for an n-bit password.
[0124] While the invention has been described by means of specific embodiments, numerous modifications and variations could be made thereto by those skilled in the art without departing from the scope and spirit of the invention set forth in the claims. | This invention discloses a method and an apparatus for processing stream encryption/decryption and more particularly to a diffusion operation of a matrix of at least one dimension including a displacement and an exclusion or (XOR), so that a plurality of diffused starting positions is converted into a diffused function operation for quickly and continuously performing an XOR operation with a plaintext (or ciphertext) stream to generate a ciphertext (or plaintext) stream. | 7 |
FIELD OF THE INVENTION
The present invention generally relates to chemical or biological attack detection and mitigation systems, and more particularly to chemical or biological attack detection and mitigation systems for buildings.
BACKGROUND OF THE INVENTION
The recent demise of the cold war and decline in super-power tensions has been accompanied by an increase in concern over the viability of weapons of mass destruction, such as chemical and biological (CB) weapons. CB weapons include chemical agents, such as blood, blister, and nerve agents, and biological agents, such as anthrax or small pox. CB weapons may be delivered to occupants within a building by releasing the agents external to the building, but close to an air intake of the building. The air intake may be located near the ground, near the roof, or somewhere in between, depending on the building architecture. Agents may also be released within a public area of a building, and be dispersed to other, private areas of the same building. Agents released in one area of a building may be further dispersed by the heating, ventilating, and air conditioning (HVAC) system of the building. Therefore, the HVAC system may effectively deliver an agent from one room to the entire building. While the agent is being delivered through the building, the location of the agent source may remain unknown, as well as the extent of the harm caused.
There are various agent delivery mechanisms. For example, agents may be delivered in vehicles giving some warnings as to the delivery, such as missiles. Agents may also be delivered in vehicles giving no warning, such as a pedestrian held putative asthma inhaler activated near an air intake in the building.
Certain buildings, such as key military sites, can be equipped or designed well in advance to deal with the use of CB weapons. Such buildings may include elaborate, built-in fixed chemical and biological sensors. Such fixed sensors, even when thorough, are generally limited to sensing one area of a building, and may be too expensive to place in all desired areas of a building. Some buildings, however, such as hotels, may be more susceptible to a CB weapons attack, lacking even fixed sensors. What would be desirable, therefore, are chemical and biological sensors that can be deployed at multiple locations in a building. What would also be advantageous are sensors that are able to search for and identify the location of harmful agents. Devices able to assist building inhabitants during an attack would also be valuable.
SUMMARY OF THE INVENTION
The present invention includes systems for detecting agents harmful to human life in buildings. The systems can include a self-propelled harmful agent detector for traversing spaces anywhere in buildings. The self-propelled agent detectors can include a harmful agent sensor for sensing chemical and/or biological agents injurious to human health, with the harmful agent sensor having a data output. A transmitter can be coupled to the harmful agent sensor data output for transmitting data from the self-propelled harmful agent detector to a receiver. A power source can supply a motor having a moving output, with a traction device coupled to the motor moving output for moving the self-propelled harmful agent detector. One embodiment has a rotating shaft as the motor moving output, with the rotating shaft coupled to at least one wheel. Some embodiments use wheels as a traction device, other embodiments utilize tracks, and still other embodiments utilize capstans for moving the detector along suspended wires or strings. Some devices use take-up pulleys or winches to move the device up and down along strings or wires.
Some detectors have sensors that can measure levels of harmful agent concentration, wherein the sensor data contains data indicating harmful agent levels, and the transmitter can transmit the agent level data. Sample traps, such as vacuum vessels or adhesives, may be included in some devices to capture samples for later analysis. Some detectors can identify the type of the harmful agent and transmit that as well. Many detectors according to the present invention also broadcast the identity and absolute or relative location of the detector. Devices may have cameras and transmitters coupled to the cameras for transmitting images near the detectors to a receiver. Such mobile transmitting cameras may be used to transmit images including victim location.
Systems incorporating moving detectors according to the present invention are also provided. Systems can include receivers for receiving data transmitted by the moving detectors. The received information can include the mobile detector ID, the type of agent detected, the agent level detected, and the location of the detector. Some systems include machine intelligence for propelling the detector toward areas having higher harmful agent concentrations. Some mobile detectors have repeating capabilities, for receiving and re-transmitting signals received from other mobile detectors in order to extend the range of transmitters, which may be disposed in areas not conducive to RF transmissions, such as within air ducts. Some systems have mobile agent detector location systems, such as a triangulation system within a building, in order to locate the position of a transmission without requiring a mobile detector to have knowledge of its position.
Some embodiments of the invention, in addition to collecting and transmitting data, can assist building inhabitants. One class of devices according to the present invention can carry information, guidance, life support equipment, and even decontamination equipment to people located within a building. One such device is large enough to carry air bottles, air packs, face masks, breathing filters, protective garments, and communication gear within the device. Some devices transmit photographic views of the area surrounding the device to a central site. Other embodiments include speakers and/or changeable message signs which can be used to transmit instructions to building inhabitants. One use of such devices is to find a safe egress route from a building that is contaminated, and instruct building inhabitants as to the route and/or instruct the building inhabitants to “follow me.”
Methods according to the present invention include providing the mobile detectors and/or receiving systems described above. The mobile harmful agent detectors can be disposed within the building and allowed to move throughout the building, and transmit information related to any harmful agent present. Some methods include mobile detectors disposed and programmed to roam outside of a building. Mobile detectors can be disposed along building floors, within air ducts, disposed along suspended wires, strings, or shafts, and hung from hanging wires, strings, ribbons, or pendulums, both within open atriums and within vertical air shafts. Some systems move the self-propelled detectors by providing the motor on one end of a string or wire and the detector on the other end. The detector is then moved by advancing the motor to move the string or wire. Other systems provide a fixed string or wire, with the detector and motor moved together. Flying mobile detectors, for example, sensors mounted on micro air vehicles (MAVs), are also included within the invention.
Some methods include providing self-propelled detector sensors to measure levels of harmful agent concentration, wherein the transmitted sensor data contains data indicating harmful agent levels, which is received and stored. Other methods include directing self-propelled mobile detectors to areas of interest, where the direction is provided from a central controller, either machine or human. In some systems, a central computer creates maps of agent type and/or intensity using the data provided by the mobile detectors.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a highly diagrammatic, perspective, cutaway view of a conventional building HVAC system shown delivering a harmful agent from a public area return air duct to private areas in the building interior;
FIG. 2 is a highly diagrammatic, side view of a mobile harmful agent detector device having a power source, controller, transmitter, motor, and wheels for traction;
FIG. 3 is a highly diagrammatic, side view of a mobile harmful agent detector device similar to that of FIG. 2, but having a track for traction;
FIG. 4 is a highly diagrammatic, side view of a mobile harmful agent detector device similar to that of FIG. 2, but having legs for traction;
FIG. 5 is a highly diagrammatic, side view of a mobile harmful agent detector device similar to that of FIG. 2, but having driven pulleys or capstans for traction along a wire or cable which may be substantially horizontal;
FIG. 6 is a highly diagrammatic, side view of a mobile harmful agent detector device similar to that of FIG. 5, but having driven pulleys or capstans for traction along a wire or cable which may be substantially vertical;
FIG. 7 is a highly diagrammatic, side view of a mobile harmful agent detector device similar to that of FIG. 6, but having motor driven traction pulleys or spools mounted on the mobile detector for taking up a wire or cable which may be substantially vertical;
FIG. 8 is a highly diagrammatic, side view of a mobile harmful agent detector device similar to that of FIG. 7, but having motor driven traction take up pulleys or spools mounted on the opposing end of a wire or cable which may be substantially vertical;
FIG. 9 is a highly diagrammatic, side view of a mobile harmful agent detector which can be used to transmit pictures to a remote site, transmit information to building inhabitants, and carry safety equipment to inhabits; and
FIG. 10 is a block diagram of a system for communication with and coordination of mobile harmful agent detectors.
DETAILED DESCRIPTION OF THE INVENTION
Various embodiments of the invention are described below in some illustrative examples of the invention. Such examples are intended to be illustrative rather than limiting. Identical reference numerals are used across the multiple figures to describe identical or similar elements, which are not reintroduced with each figure.
FIG. 1 illustrates a building 20 including a public atrium area 23 and having a conventional building heating, ventilating, and air conditioning (HVAC) system 22 not having any duct isolation equipment in place. HVAC system 22 is illustrated transporting harmful agent 46 through return air ducts 34 and dispersing it as externally released cloud 44 . Air intake 24 and exhaust 26 are connected to a series of ducts including large, usually rectangular chambers or ducts such as chamber 28 , and intermediate sized, usually rectangular, ducts 30 . Intermediate ducts 30 split off into a series of smaller, often circular, ducts 32 , which feed a series of room diffusers 38 . Return air vents 36 and return air ducts 34 return air to either be expelled outside the building or be mixed with fresh air intake. Heating, cooling, humidification, and dehumidification functions are often performed in large chambers such as chamber 28 , and in more local intermediate sized chambers 42 . Mixing and/or recirculation can be performed by a return air duct 48 .
FIG. 1 illustrates an internally released harmful agent cloud 46 dispersed in public atrium 23 near return air vents 36 . HVAC system 22 is illustrated transporting harmful agent 46 through return air ducts 34 and dispersing it as externally released cloud 44 . Return air ducts 34 are also connected through return air duct 48 , into intake chamber 28 , and may internally release harmful agent cloud 47 through diffusers 38 . As illustrated, the harmful agent is delivered from a public portion of the building to the private areas of the building by the HVAC system and to the exterior near the building as well.
FIG. 2 illustrates a mobile, self-propelled harmful agent detector device 100 , having a chassis or body 102 , a first wheel set 116 , a second wheel set 122 , a harmful agent sensor 104 , a controller 108 , a power source 120 , a motor 118 , and a transmitter 112 . Controller 108 is coupled to agent detector 104 through a data communication line or channel 106 , which can be, for example, any suitable electrical or optical line, wire, or channel. As used herein, “harmful agent sensor or detector” means a sensor or detector for sensing, measuring, or detecting agents harmful to humans, including chemical and biological agents. The terms “harmful agent sensor or detector” and “agent sensor or detector” are intended to convey the same meaning as used herein. Although any suitable detector either known or unknown at the present time may be used, the agent detectors can include, for example, spectrographic analyzers including visible, infrared, near infrared, ultraviolet, and/or fluoroscopic. So-called “chemical noses” or “electrical noses” may be used to identify agents. Portable mass spectrometers may also be used. Portable bioassay devices, reagents, and readable test strips may also be used as agent detectors, if desired.
In some embodiments, a harmful agent trap is included. Agent traps can include vacuum bottles having controllable inlet valves, or other sampling devices, well known in industrial hygiene monitoring applications. Filter traps and adhesive traps may also be included, and can be used to trap samples for later analysis. In some embodiments, a camera is included with, or in place of, harmful agent sensor 104 , with a picture being transmitted either in addition to, or in place of, harmful agent concentration data. In embodiments having only a camera, for example, reference numeral 104 may be understood to refer to a camera.
Controller 108 may be coupled to transmitter 112 through a data line 110 , and is illustrated transmitting data indicated at 114 . Any suitable transmitter may be used, including radio frequency (RF) and optical transmitters. While the term “transmitter” is used to denote one function of the mobile detector, the transmitter in a preferred embodiment is a transceiver, able to both transmit and receive information.
Power source 120 may be a battery and is preferably coupled to motor 118 . Power sources may be either fixed to the mobile detector, or located apart from the mobile detector and coupled to the detector by wires. Controller 108 can be coupled to motor 118 through a control line 109 , which can be used to control the motor driving the wheel or wheels. In one embodiment, first wheel set 116 are drive wheels and second wheel set 122 are turnable or steerable wheels, under the control of controller 108 . In some embodiments, mobile detector 100 is self-aware of its position, and can transmit that position to a receiver. In other embodiments, mobile detector 100 transmits a signal which can be triangulated upon by multiple receivers. In still other embodiments, mobile detector 100 can count its relative progress along a known route, by inches, clicks, or wheel rotations, with the relative progress into the route ascertainable by the mobile detector and/or a central receiving unit. In a preferred embodiment, the ID of the mobile detector is transmitted along with any other data. In one embodiment, the mobile detector includes a transceiver and may be programmed to retransmit data received from other mobile detectors, having different IDs, thereby allowing the mobile detectors to act as relays. This may be useful for embodiments having short transmission ranges, or detectors disposed within metal air ducts.
Mobile detector 100 utilizes wheels 116 and 122 as traction devices. The wheels may be formed of a rubber material or other polymer suitable for providing traction. Mobile detector 100 may be used to traverse floors, air ducts, crawl spaces, false ceilings, or any surface the wheels are able to engage. In mobile device 100 , motor 118 is mounted on body 102 such that motor 118 travels together with body 102 . In some devices, discussed below, the propelling motor is fixed to another object and remains in one location while propelling the body, for example, through a tether. In either case, the mobile detector may be self-propelled.
FIG. 3 illustrates a mobile detector 130 , similar to mobile detector 100 of FIG. 2, but utilizing tracks or treads 139 disposed over three wheel pair sets 132 , 133 , and 134 . Tracks or treads may be more useful in traversing unfriendly terrain than wheels alone. In some devices, tracks are sufficiently long to enable climbing stairs.
FIG. 4 illustrates a mobile detector 160 , similar to mobile detector 100 of FIG. 2, but utilizing legs 168 disposed in three pairs on a chassis or body 164 . Legs may be motor driven by a motor 166 to enable the device to crawl over uncertain terrain, and may be more useful in traversing unfriendly terrain than wheels.
FIG. 5 illustrates a mobile detector 180 , similar to mobile detector 100 of FIG. 2, but utilizing pulleys or capstans 182 , 184 , 186 , and 188 , which are supported by legs 190 secured to body 102 and disposed about a wire, cable, string, shaft, or ribbon 181 . Wire 181 may be substantially horizontal in some embodiments, and may be strung through air ducts, under computer room raised floors, through crawl spaces, between buildings, and across building atriums. In some embodiments, the gap between the upper and lower wheels, 182 and 184 , and 186 and 188 , respectively, may be relatively large, and gravity relied upon to provide traction between driven upper wheels 182 and 186 and wire 181 . In other embodiments, the gap between the upper and lower wheels, 182 and 184 , and 186 and 188 , respectively, may be relatively small, and a tight fit between wheels and wire is relied upon to provide traction. In embodiments having a tight fit, enabling the wheels to grasp wire 181 , either upper wheels 182 and/or 186 , or lower wheels 184 and/or 188 , or both, may be driven by motor 118 . In some embodiments, mobile detector 180 travels between two extreme limits of travel, reversing direction when either limit is reached. In some devices, a count of wheel revolutions or similar measure is used to measure travel and can be used to calculate relative location along the route.
FIG. 6 illustrates a mobile detector 200 , similar to mobile detector 180 of FIG. 5, but utilizing pulleys or disposed about a wire, cable, string, shaft, or ribbon 232 . Wire 232 is illustrated as fixed to support member 230 , which may be a ceiling in some applications. Wire 232 may be substantially vertically disposed in some embodiments, and may be strung through air ducts, wall spaces, elevator shafts, and building atriums. In a preferred embodiment, the gap between wheel pairs, 182 and 184 , and 186 and 188 , may be relatively small, and a tight fit between the wheels and wire 232 is relied upon to provide traction. In embodiments having a tight fit, enabling the wheels to grasp wire 232 , either wheels 182 , 186 , 184 and/or 188 , may be driven by motor 118 . In some embodiments, wire 232 is serrated, having teeth or other demarcations, providing improved traction. In some embodiments, at least some of the driven wheels are also serrated or have teeth to provide better traction. In some devices, both wire or ribbon 232 and the driven wheels have matching sized teeth, to provide a track for the wheel teeth to engage for better traction. In some embodiments, mobile detector 200 travels between two extreme limits of travel, reversing direction when either limit is reached. In some devices, a count of wheel revolutions or similar measure is used to measure travel and can be used to calculate relative location along the route.
FIG. 7 illustrates a mobile detector 220 , similar to mobile detector 200 of FIG. 6, but utilizing a take-up pulley or spool 226 to take up a wire, cable, string, or ribbon 234 suspended from support member 230 , which may be a ceiling in some applications. Wire 234 may be substantially vertically disposed in some embodiments, and may be strung as discussed with respect to wire 232 or FIG. 6 . Motor driven take-up spool or pulley 226 is secured to body 224 , and can wind wire 234 about the spool as the spool is driven, thereby providing the traction, and pulling mobile detector 220 upward. Downward movement may be provided by reversing the motor direction or by allowing take-up spool 226 to unwind, either controllably or rapidly, depending on the embodiment. In some devices, a count of spool revolutions or similar measure is used to measure travel and can be used to calculate relative location along the route.
FIG. 8 illustrates a mobile detector 240 , similar to mobile detector 220 of FIG. 7, but utilizing motor 244 driving a take-up pulley or spool 246 to take up wire, cable, string, or ribbon 234 suspended from support member 230 , which may be a ceiling in some applications. A control and/or power line 242 may be coupled to motor 244 to provide power and/or control for the device. Motor driven take-up spool or pulley 246 is secured to motor 244 , and can wind wire 234 about the spool as the spool is driven in some embodiments, thereby providing the traction, and pulling mobile detector 240 upward. Downward movement may be provided by reversing the motor direction or by allowing take-up spool 246 to unwind, either controllably or rapidly, depending on the embodiment. Mobile detector 240 may be said to be self-propelled, but having the motor fixed at the opposing end of a tether, rather than moving with the mobile detector. As previously discussed, the location of the detector may be measured and transmitted along with other data related to agent detection.
FIG. 9 illustrates a mobile self-propelled harmful agent detector 400 , having lights 446 and wheels 404 mounted on body 402 , the wheels driven by motor 406 . Mobile detector 400 includes a controller 430 coupled to other components through control lines 410 . Unless otherwise indicated, lines 410 illustrated in FIG. 9 are power and/or control lines, which can be used to provide power and/or transmit and receive data between the various components. Controller 430 can be coupled to a transmitter 426 for transmitting and receiving data 428 as illustrated. As previously discussed, the transmissions may be through any suitable medium including RF and IR. In one embodiment, mobile detector 400 is capable of carrying life support equipment for building inhabitants, and of providing assistance during an emergency.
A camera head 416 having multiple cameras 418 is disposed on a neck member 420 , which can preferably be controllably turned to face directions determined by a remotely located operator. Images provided by cameras 418 may be transmitted back to a receiver. In one embodiment, neck 420 is fixed, with the multiple cameras being selectable to provide different views. In some embodiments, microphones 414 or other sensors are disposed along the body sides to listen for noises, for example, human voices. The sound signals thus received may also be transmitted back to a receiver.
A sensor head 408 is also illustrated, which may be rotated about a rotatable neck member 412 . Sensor head 408 may include multiple harmful agent sensors including arrays or different sensors to be used in chemical analysis. Sensor head 408 may include air intake or suction ports to be used, for example, to feed chromatographic or other instruments within body 402 . Sensor head 408 is illustrated as coupled to a sensing analysis unit 422 which is in turn coupled to controller 430 . Sensor head 418 may be rotated in some devices, so as to take samples from different directions.
Mobile detector 400 may include communications devices intended to communicate with humans who may be located within a building, unsure of what to do. In particular, building inhabitants may be unsure if they should attempt to leave a building, or unsure of what route may be safe to take out of a building. To this end, mobile detector 400 may include a changeable message sign 424 , having, for example, a large, light emitting diode (LED) scrolling display with useful information. Such a display may be controlled by a central controller through transceiver 426 .
Similarly, a loudspeaker 440 may be used to inform building inhabitants as to a safe route to take out of the building, or may inform the inhabitants to remain in place. Loudspeaker 440 may be coupled through transceiver 426 and may be used in conjunction with microphones 414 to allow a remote operator engage in conversations with people.
Mobile detector 400 may also contain decontamination equipment, for example, a canister of decontamination fluid or foam 436 coupled to a decontamination nozzle 432 through a pipe or tube 434 . In some embodiments, pipe 434 can be controllably rotated and aimed by a remote operator, with the decontamination fluid or foam controllably ejected by a remote operator, or even by a local person following proper instructions.
A door 444 may be attached to body 402 , and be opened through use of a handle 438 . A sign 442 may be used to indicate to persons located nearby that there is safety equipment inside. In one embodiment, door 444 is attached to body 402 with hinges. Safety gear disposed within body 402 can include oxygen tanks, regulators, air bottles, air packs, respirators, first aid equipment, filter masks, decontamination equipment, protective garments, and communication equipment, such as portable radios or telephones.
In one use of mobile agent detector 400 , mobile agent detector, either alone or using externally provided information, locates a safe egress path through a building believed to be otherwise contaminated, or under harmful agent attack. With the route located, mobile agent detector 400 may travel through the building, informing personnel within of the safe egress route. One method includes having mobile agent detector 400 informing people that a safe route is to be had by following the mobile detector to a destination, which may be an outside exit or an inside safe room.
FIG. 10 illustrates a mobile agent detector system 300 , including a central controller or computer 302 , and a transceiver 306 with antenna 308 . An operator interface device 310 , for example a CRT or console, is coupled to controller 302 by a communications line or channel 312 . Transceiver 306 is coupled to controller 302 by a data communications line or channel 304 .
Controller 302 preferably includes a computer, and operator interface device 310 preferably includes a display screen. Controller 302 can be used to coordinate the movement of numerous mobile detectors, for example, mobile detectors 100 , 130 , 160 , 180 , 200 , 220 , 240 , and 400 . In one embodiment, controller 302 directs the mobile detectors to execute preassigned roaming modes, while tracking, recording, and plotting any possible harmful agents detected. When there is a precipitating event, such as a high concentration measured for a harmful agent, controller 302 may take a more active role.
In one method, controller 302 may assign the more intrusive mobile detectors, for example the wheeled, steerable detectors, to roam the building floors, out in the open, searching for high concentrations of harmful agents. In one method, mobile detectors able to steer themselves toward higher concentrations are allowed to do so. As the detectors gather data, hot spots, or high concentration areas of harmful agents, are searched for, recorded, plotted, and analyzed by controller 302 and, in some embodiments, analyzed by a human operator.
In one illustrative example, a mobile detector, such as detector 240 , may detect a harmful agent concentration near a specified floor level of a large, central return vertical air duct, while an elevator shaft mounted detector confirms the specified floor as a high concentration area. One mobile detector, such as detector 180 , may indicate the presence of an agent in a smaller horizontal return air duct near that floor, at a specific location of travel. At the same time, a mobile detector within a supply duct for that floor may indicate that no agent has been detected. This may rapidly pinpoint the source of the agent.
In response, the proper air handling motors, dampers, and blowers may be controlled, and turned on or off, in order to limit the spread of the harmful agent, or even force the harmful agent from the building. Mobile detectors such as wheeled detectors 100 , 130 , or 160 may be instructed to roam the specified and adjoining floors, while remote detector 400 may be sent to the specified floor to provide assistance. By way of comparison, the same number of fixed detectors in the same building may only indicate that there is a harmful agent somewhere in the building, later confirmed by reports of people being harmed, after the agent has been allowed to further spread.
Numerous advantages of the invention covered by this document have been set forth in the foregoing description. It will be understood, however, that this disclosure is, in many respects, only illustrative. Changes may be made in details, particularly in matters of shape, size, and arrangement of parts without exceeding the scope of the invention. The invention's scope is, of course, defined in the language in which the appended claims are expressed. | Systems and methods for monitoring buildings to detect harmful chemical or biological agents. Self-propelled harmful agent detectors are provided that can propel themselves using motors and self-contained power sources. On-board harmful agent sensors can detect the presence of harmful agents and transmit information for reception by a receiving unit. Some sensors can identify the type of agent and transmit the agent type. Some detectors can measure the intensity or concentration of the harmful agent presence and transmit that intensity. Some systems include locating devices for determining positions of the roaming detectors, as well as mapping software to map the location of the individual moving detectors. Systems may include software for plotting the relative concentrations of agents detected to locate the origination of the source within the building. The moving detectors can have motors coupled to wheels, tracks, capstans, pulleys and winches to move the devices along floors, air ducts, and suspended or hanging wires. | 8 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of priority pursuant to 35 U.S.C. §119(e) of U.S. provisional application No. 61/078,278 filed 3 Jul. 2008 entitled “Insulating glass unit as shipping container,” which is hereby incorporated herein by reference in its entirety.
BACKGROUND
[0002] 1. Technical Field
[0003] The technology disclosed herein relates to the use of an insulating glass unit as a container for the shipping and storage of a thermoreflective filter.
[0004] 2. Description of the Related Art
[0005] The energy benefits of double-paned windows have been known since Roman times, although double-paned windows did not evolve into widely used, standardized forms until the latter half of the 20th century, when the insulating glass unit, or IGU, became the most common type of window glazing, both in the United States and elsewhere in the developed world. The design, composition, assembly, packaging, storage, shipping, installation, and use of IGUs are well documented in the public domain and need no further elaboration here, except to say that the air gap between the panes of an IGU provides a dry, airtight, hermetically-sealed environment.
[0006] U.S. patent application Ser. No. 12/172,156 to Powers et al. discloses a “thermoreflective” window filter that is largely transparent when cold and largely reflective when hot, and can be used to regulate the temperatures of buildings when incorporated into windows. By the nature of their design and construction, many embodiments of this technology are large, thin, rigid, and complex in their internal structure, often including microscopic or nanoscopic optical components including, but not limited to, thin films, thin sheets, spacer beads, laminates, and highly ordered nanophotonic materials. In addition, because many of these components may be made of glass, the resulting thermoreflective filter can be both heavy and fragile, and also potentially hazardous when broken.
[0007] Switchable mirrors as described, for example, in U.S. Pat. No. 7,042,615 to Richardson are based on reversible metal hydride and metal lithide chemistry. These switchable mirrors rely on the physical migration of ions across a barrier under the influence of an electric field, and therefore have limited switching speeds and cycle lifetimes. Electrically operated “light valves” as described, for example, in U.S. Pat. No. 6,486,997 to Bruzzone, et al., combine liquid crystals with one or more reflective polarizers. In these devices, the liquid crystal typically serves as an electrotropic depolarizer, i.e., a means of rotating the polarity of the light that passes through it under the influence of an electric field. Some of these devices can be thought of as switchable mirrors, although they are rarely described that way, since their primary application is in video displays and advanced optics. Such filters, switchable mirrors, light valves, and similar devices represent a serious challenge for handling, storage, shipping, and installation.
[0008] Many types of shipping or storage containers have been used including, but not limited to, racks, shelves, boxes, cases, pallets, padded separators, and glue trays. One known type of shipping container called a glue tray or gel pack affixes thin, rigid objects such as semiconductor wafers to the bottom surface of the tray by a layer of adhesive to shield the objects from shock, vibration, abrasion, mechanical stress, or other damage. Such containers and their contents are generally insensitive to orientation or to rough handling, provided the casing itself is not dented or breached. For this reason such containers have become a standard method for shipping flat, thin, rigid objects—including objects of considerable size, for example, large semiconductor wafers, wire grid polarizers, and microscope slides. However, such gel pack- or glue tray-type enclosures do not, in addition to serving as shipping containers, also serve as the final operational housing for the item being shipped.
[0009] The information included in this Background section of the specification, including any references cited herein and any description or discussion thereof, is included for technical reference purposes only and is not to be regarded as subject matter by which the scope of the invention is to be bound.
SUMMARY
[0010] The technology disclosed herein is directed to the use of an insulating glass unit (IGU) as a shipping and storage container for thin, flat, fragile objects, e.g., a thermoreflective filter. Because many types of thermoreflective filters are thin, heavy, fragile, rigid, or a combination thereof and thus difficult to handle, they must be packaged carefully for shipping, storage, and other handling such as during installation in the skin of a building.
[0011] In one implementation, the shipping and storage container for a thermoreflective filter switchable mirror, glass valve, or similar thin, fragile, heavy, and/or rigid device (hereafter “thin, fragile devices”) consists of two thick sheets of rigid glass, separated by an edge spacer and held together with an adhesive sealant, for example, hot-melt polyisobutyl (PIB). In other words, the shipping container is functionally identical to and capable of serving as the IGU in which the filter will ultimately be employed operationally, for example, as fenestration in a building. In one implementation, the thermoreflective filter maybe affixed to a large, flat surface of one of the glass sheets of the container by an adhesive that is both optically clear and permanent. This prevents an air gap from forming between the filter and the IGU glass, which minimizes reflection losses from the index of refraction mismatch between glass and air.
[0012] This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter. A more extensive presentation of features, details, utilities, and advantages of the present invention is provided in the following written description of various embodiments of the invention, illustrated in the accompanying drawings, and defined in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] Please note that closely related elements have the same element numbers in all figures.
[0014] FIG. 1 is from the prior art, and is a schematic, cross-section view of a typical thermoreflective filter in its cold or transmissive state.
[0015] FIG. 2 is a from the prior art, and is a schematic, cross-section view of the same thermoreflective filter in its hot or reflective state.
[0016] FIG. 3 is from the prior art, and is a schematic representation of another type of thermoreflective filter, in which the thermoreflective filter is an electrorefletive filter with one or more temperature sensors and a control system.
[0017] FIG. 4 is an exploded view of the thermoreflective filter in its shipping container.
DETAILED DESCRIPTION OF THE INVENTION
[0018] The structure, composition, manufacture, and function of insulating class units (IGUs) are well documented. However, the idea of a shipping container made of an IGU may seem counterintuitive. Although IGUs are rarely employed as load-bearing members in a structure, they are generally robust enough to resist shattering during normal handling and operation. It is therefore common practice to construct IGUs from tempered, heat-strengthened, annealed, chemically strengthened, or laminated glass. Even in cases where ordinary float glass, plate glass, or blown glass is used to construct the IGU, the glass is often 6 mm thick or more, giving it considerable shatter resistance and compressive strength. In addition, IGUs are typically stored and shipped in racks, with little or no additional packaging to protect them. Thus, an IGU may function as an adequate shipping container for a thermoreflective filter or other thin, fragile device.
[0019] FIGS. 1 and 2 are from U.S. patent application Ser. No. 12/172,156 to Powers et al., and are schematic, cross-section views of an exemplary form of thermoreflective filter 100 which includes a depolarizer layer 102 sandwiched between two reflective polarizing filters 101 and 103 , and which is attached to an optional transparent substrate 104 . Incoming light first passes through the outer reflective polarizer 101 . Of the incoming light, approximately 50% will have polarization perpendicular to that of the polarizer 101 and will be reflected away.
[0020] Once it has passed through the outer reflective polarizing filter 101 , the incoming light enters the thermotropic depolarizer 102 , which is a device or material capable of exhibiting two different polarizing states. In a hot or isotropic or liquid state, the polarized light passing through the thermotropic polarizer 102 is not affected. In a cold (e.g., nematic or crystalline) state, the thermotropic depolarizer 102 rotates the polarization vector of the incoming light by a fixed amount.
[0021] Once the light has passed through the thermotropic depolarizer 102 , the remaining polarized light strikes the inner reflective polarizer 103 , also known as the “analyzer,” where it is either reflected or transmitted, depending on its polarization state. The inner reflective polarizer 103 is oriented such that its polarization is perpendicular to that of the outer reflective polarizer 101 . Thus, in the hot state of the thermoreflective filter 100 , when the polarization vector of the light has not been rotated, the polarity of the light is perpendicular to that of the inner reflective polarizer 103 , and approximately 100% of it is reflected. However, in the cold state, when the polarization vector of the light has been rotated by 90 degrees and is parallel to the inner reflective polarizer 103 , a small amount of the light is absorbed by the inner reflective polarizer 103 , and the rest is transmitted through.
[0022] In FIG. 1 , the action of incoming light is depicted for the cold state of the thermoreflective filter 100 , wherein the outer reflective polarizer 101 reflects approximately 50% of the incoming light. The remaining light passes through the thermotropic depolarizer 102 where the polarization vector of the light is rotated, and then through the inner reflective polarizer or analyzer 103 where the light is largely unaffected. It then passes through an optional transparent substrate 104 , and finally exits the device 100 . Thus, in its cold state the device 100 serves as a “half mirror” that reflects approximately 50% of the light striking its outer surface, absorbs a small amount, and transmits the rest through to the inner surface.
[0023] In FIG. 2 , the action of incoming light is depicted for the hot state of the filter device 100 . As in FIG. 1 , the outer reflective polarizing filter 101 reflects approximately 50% of the morning light. However, in the hot state the thermotropic depolarizer 102 does not affect the polarization vector of the light passing through it. Thus, any light striking the inner reflective polarizer is of perpendicular polarity to it, and approximately 100% is reflected back. The filter device 100 therefore serves as a “full mirror” that reflects approximately 100% of the light striking its outer surface. Thus, in its cold state the device 100 transmits slightly less than half the light energy that strikes its outer surface, whereas in the hot state the device 100 transmits substantially less than 1 % of the light energy. As a result, the filter device 100 can be used to regulate the flow of light or radiant heat into a structure based on the temperature of the filter device 100 .
[0024] FIG. 3 is also from U.S. patent application Ser. No. 12/172,156 to Powers et al. and is a schematic representation of another type of thermoreflective filter 100 ′, in which the thermotropic depolarizer 102 has been replaced with an electrotropic depolarizer 102 ′, plus two transparent electrodes 107 and a control system 108 , which collectively perform the same function as the thermotropic polarizer 102 and FIGS. 1 and 2 . The operation and use of this embodiment are otherwise identical to operation and use of the embodiment shown in FIGS. 1 and 2 .
[0025] FIG. 4 is an exploded view of an exemplary implementation of a shipping container 400 for a thin, fragile device 401 . As contemplated herein, a thin, fragile device 401 may be rigid or flexible, heavy or light, smooth or rough, and combinations thereof depending upon the materials used to construct the thin, fragile device 401 . The thin, fragile device 401 , e.g., a thermochromic filter as described above, may be affixed by an adhesive layer 402 to a lower glass pane 403 within the space formed by a spacer 404 . Exemplary forms of the spacer 404 for the shipping container include rectangular frames made from hollow, rectangular tubes of aluminum or stainless steel, or alternatively, polymer spacers. An upper glass pane 405 is then placed on top of the spacer 404 , and the enclosure is sealed, typically with a hot-melt adhesive such as polyisobutyl (PIB). It should be understood that other sealing methods could be used as well, including methods where the seal and the spacer 404 are combined as a single object, without altering the fundamental nature of the IGU or its operation as a shipping and storage container 400 .
[0026] Thus, the IGU forms a shipping container 400 . The lower glass pane 403 forms the bottom of the container, the spacer 404 serves as the sidewalls, the upper glass pane 405 serves as the top, and the adhesive layer 402 secures the thin, fragile device 401 within the shipping container. In this configuration, the container 400 can be tilted, shifted, rotated, subjected to reasonable shock and vibration, or otherwise manipulated without harm to the thin, fragile device 401 . Because the IGU is both sealed and composed of inert materials, the container 400 also protects the thin, fragile device 401 from dust, moisture, abrasion, chemical or particulate contamination, in a way that other container types (including but not limited to carboard boxes, wooden crates or pallets, padded separators, and wire racks) cannot.
[0027] Many optional enhancements can be made to this design without altering its fundamental nature. For example, the spacer 404 may be hollow, and filled with a dessicant material such as powered silica to remove moisture from, and prevent fogging of, the IGU interior. Alternatively, the spacer 404 may be filled with a phase-change material or high-thermal-mass material to minimize temperature fluctuations. Multiple filters or other devices may be placed side by side on the adhesive layer 402 . In another embodiment, the thin, fragile device 401 may be affixed mechanically (e.g., with clips or brackets) to the IGU in addition to, or instead of, the adhesive layer 402 . However, it should be understood that if an air gap exists between the thermoreflective filter 401 and the glass pane 403 , there will be a reflection loss at each additional air/solid interface.
[0028] While several exemplary embodiments are depicted and described herein, it should be understood that the disclosed shipping container is not limited to these particular configurations. Optional components such as coatings, films, or fill gases may be added to suit the needs of a particular application or a particular manufacturing method, and degraded forms of some embodiments may be produced by deleting or substituting certain components. For example, the IGU glass may be replaced with a transparent polymer such as acrylic, forming an insulating polymer unit and similarly function as a shipping and storage container for a thin, fragile device. Alternatively, one or more air vents could be placed in the edge seal to allow pressures to equalize when changing altitude during transport. Furthermore, while the IGU makes a particularly useful shipping container for brittle objects, it can equally be used to ship flexible filters.
[0029] The exact arrangement of the various layers can be different than is depicted here and (depending on the materials and wavelengths selected) different layers can be combined as single layers, objects, devices, or materials, without altering the essential structure and function of the shipping container. For example, the lower pane of the IGU could serve as part of the structure of the thermoreflective filter itself, e.g., as a polarizer, transparent substrate, and/or liquid crystal alignment layer.
[0030] Thus, a shipping container for a thermoreflective filter or other thin, fragile device has been disclosed that protects the devices from various types of harm including humidity, corrosion, shock, vibration, mechanical stress, and scratching. The shipping container may also serve as the functional enclosure for the thermoreflective filter or other thin, fragile device in its end use as a building material, thus eliminating the need to create a separate shipping container in addition to the functional enclosure. The shipping container provides an adhesive layer to prevent the thermoreflective filter from moving inside the container, thus preventing damage to the filter when the container is tipped, reoriented, shaken, or otherwise disturbed. The adhesive layer provides an optically clear bond between the thermoreflective filter and the IGU glass, thus minimizing the reflection losses that would occur within an air gap. The storage and shipping container requires little or no additional packaging for safe storage and shipping. The use of an IGU as a shipping and storage container minimizes the overall handling to which the thermoreflective filter or other thin, fragile devices may be subjected between the time of its manufacture and the time of its final installation in a structure.
[0031] All directional references (e.g., proximal, distal, upper, lower, upward, downward, left, right, lateral, front, back, top, bottom, above, below, vertical, horizontal, clockwise, and counterclockwise) are only used for identification purposes to aid the reader's understanding of the present invention, and do not create limitations, particularly as to the position, orientation, or use of the invention. Connection references (e.g., attached, coupled, connected, and joined) are to be construed broadly and may include intermediate members between a collection of elements and relative movement between elements unless otherwise indicated. As such, connection references do not necessarily infer that two elements are directly connected and in fixed relation to each other. The exemplary drawings are for purposes of illustration only and the dimensions, positions, order and relative sizes reflected in the drawings attached hereto may vary.
[0032] The above specification, examples and data provide a complete description of the structure and use of exemplary embodiments of the invention. Although various embodiments of the invention have been described above with a certain degree of particularity, or with reference to one or more individual embodiments, those skilled in the art could make numerous alterations to the disclosed embodiments without departing from the spirit or scope of this invention. Other embodiments are therefore contemplated. It is intended that all matter contained in the above description and shown in the accompanying drawings shall be interpreted as illustrative only of particular embodiments and not limiting. Changes in detail or structure may be made without departing from the basic elements of the invention as defined in the following claims. | An insulating glass unit (IGU) is used for storing and transporting thermoreflective filters or other thin, fragile devices, chiefly because such filters are often fragile and heavy. Because the IGU may also be the functional enclosure for the thermoreflective filter when it is installed in a building, using the IGU as a shipping container minimizes the total handling of the unpackaged filter and therefore minimizes the risk of damage or breakage. | 1 |
FIELD OF THE INVENTION
[0001] This invention is directed to devices operative in response to impingement by high energy photons, and, more particularly, to a passive energy source which exploits the electrical characteristics of metals having different atomic numbers when exposed to a dosage of high energy photons such as x-rays or gamma rays.
BACKGROUND OF THE INVENTION
[0002] One of the challenges for many electronics programs is how to reduce the size and weight of electronics components. In larger systems, such as aircraft and spacecraft, every savings in size and weight increases payload and mission capabilities. It is equally important in miniature systems, such as certain types of medical devices, where each reduction can open a range of applications previously inaccessible at larger scales.
[0003] One of the key constraints in any electronics system is the demand for some form of local energy to provide power for the system components. Typical solutions include one or more forms of fuel-based power generation, such as fossil or nuclear fuels, or an energy storage device, e.g. a battery. Other applications employ “passive” energy sources such as photovoltaic panels which are commonly used in spacecraft and other equipment in which the energy source cannot be readily replaced. Solar panels, for example, tend to require a substantial amount of surface area to create useful amounts of electrical energy, adding unwanted size and weight. Further, solar panels must be directed toward the sun to operate efficiently and it can be difficult to maintain the appropriate attitude of the panels to maximize exposure to the sun.
SUMMARY OF THE INVENTION
[0004] This invention is directed to an energy cell employed as a passive energy source, which, when exposed to dosages of high energy photons such as x-rays or gamma rays, produces an induced electromagnetic force charge.
[0005] It has long been known that every metal ejects electrons from its surface in response to the impingement by photons of a sufficient energy level. The linear absorption coefficient of a particular metal is the sum of different phenomenon, including Thomson scattering, photoelectric absorption, Compton scattering, pair production and photodisintegration. Thomson scattering occurs when high energy photons, such as x-ray photons, scatter after impingement with the metal and there is no change in energy to either the atom of the metal or the x-ray photon. Photoelectric absorption occurs when the atom of a metal absorbs the x-ray photon, resulting in electrons being ejected from the outer shell of the atom and the ionization of the atom. Compton scattering occurs when an x-ray photon ejects an electron from the metal atom, and an x-ray of lower energy is scattered from the atom. At the energy levels of x-ray photons, pair production and photodisintegration have little or no effect on the linear absorption coefficient.
[0006] In the past, the ejection of electrons from the surface of metals as a result of impingement by x-ray photons or other high energy photons such as gamma rays, had adverse effects on electronic systems of all types. The ejected electrons can damage certain electrical components, interfere with the transmission and receipt of data and cause other problems. As a result, efforts were undertaken to shroud such metal surfaces from impingement by photons to protect electrical components, circuits, instrumentation and the like from damage.
[0007] This invention is predicated on the concept of using the phenomena described above to create a passive source of electrical energy which exhibits a long life and is inexpensive, highly reliable, and sensitive. It can operate in extreme environmental conditions, requires little or no maintenance and can be integrated in a wide variety of applications and structures. In the presently preferred embodiment, an energy cell is provided comprising at least one metal element having a high atomic number, at least one second metal element with a comparatively low atomic number and a section of dielectric material located between the first and second metal elements. Such “metal elements” may be plates, a wire and sheath or essentially any other configuration in which metal layers are separated by dielectric material.
[0008] In one example, the energy cell may include a plate formed of gold and another plate formed of aluminum separated by a composite layer. In response to dosage of the plates with x-rays, both the gold plate and aluminum plate eject electrons. But because the gold plate has a comparatively higher atomic number, more electrons are ejected from it than the aluminum plate. This creates an electrical potential across the plates such that when a load is connected to them electrical energy, e.g., an induced electromagnetic force (IEMF) charge, flows from the plates to the load. The energy cell of this invention can be scaled in the sense that the physical size of the metal elements can be altered, as desired, and more than one energy cell may be connected together in series or parallel to increase the overall amount of electrical energy produced depending upon the requirement of a particular application.
[0009] There are a myriad of applications with which the energy cell of this invention may be utilized, at both the macro and micro level. It may be applied at a macro level to the housing or chassis of an electronic device, or to the cables, connectors, cable harnesses etc. of same. At a micro level, the energy cell herein may be embedded in a printed wiring board, affixed as a device on a circuit board, laminated on the surface of chips, embedded within the chip circuitry as well as other options.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The structure, operation and advantages of the presently preferred embodiment of this invention will become further apparent upon consideration of the following description, taken in conjunction with the accompanying drawings, wherein:
[0011] FIG. 1 is a schematic cross sectional view of one embodiment of the energy cell of this invention shown connected to a load;
[0012] FIG. 2 is a view of an alternative embodiment of the energy cell herein;
[0013] FIG. 3 is a schematic, plan view of a circuit board employing multiple energy cells;
[0014] FIG. 4 is a cross sectional view of a stack of printed circuit boards in which energy cells of this invention are embedded at different layers.
DETAILED DESCRIPTION OF THE INVENTION
[0015] Referring now to FIG. 1 , a schematic view of one embodiment of an energy cell 10 according to this invention is depicted. In this embodiment, the energy cell 10 comprises a first plate 12 and a second plate 14 separated by a layer 16 of dielectric material such as a composite material. The plate 12 is formed of a material having a relatively high atomic number, such as gold, whereas the plate 14 is formed of a material having a comparatively low atomic number such as aluminum. The energy cell 10 is subjected to a dose of high energy photons, such as x-rays or gamma rays, as schematically shown by the brackets 18 in FIG. 1 .
[0016] As noted above, all metals eject electrons when impinged by photons of sufficient energy. Materials with higher atomic numbers eject a larger quantity of electrons than those with lower atomic numbers, assuming they are exposed to the same dosage of high energy photons, and therefore a potential difference is produced across the plates 12 , 14 which is represented by a “−” sign associated with the gold plate 12 and a “+” sign associated with the aluminum plate 14 . While both plates 12 , 14 actually exhibit a negative charge, the charge on the gold plate 12 is more negative than that of the aluminum plate 14 .
[0017] The gold plate 12 is shown connected by a lead 20 to a load 22 , and the aluminum plate 14 is connected by lead 24 to the load 22 . The term “load” as used herein is intended to broadly encompass a variety of circuits or devices which may be connected to the energy cell 10 . In one aspect of this invention, the energy cell 10 is used as a passive energy source which provides electrical energy to essentially any number of different types of electrical circuits or devices which can be operated at voltage and current levels produced by the energy cell 10 , as discussed below. Further, a suitable threshold circuit and driver circuit (not shown) may be interposed between the energy cell 10 and load 22 which collectively function to store electrical energy produced by the energy cell 10 and then discharge it to a circuit or device when it reaches a predetermined level. It should be noted that electrons are ejected by the plates 12 , 14 only when they are impinged by the high energy photons, and in the absence of such photons the ejected electrons dissipate. As such, a storage device such as a conventional capacitor or threshold circuit may be employed to capture the electrical energy produced when the energy cell 10 is dosed with x-rays or other high energy photons.
[0018] FIG. 1 depicts one example of an energy cell according to this invention. It should be understood that other configurations of metal structures having different atomic numbers, separated by a dielectric material, can form an energy cell which is considered within the scope of this invention. For example, in FIG. 2 an energy cell 26 is shown which consists of an insulated wire 28 surrounded by a sheath 30 . The insulated wire 28 has a core 32 of aluminum or a similar material with a relatively low atomic number surrounded by a rubber insulator 34 , and the sheath 30 is preferably formed of gold or other material with a comparatively high atomic number. The energy cell 26 of this embodiment functions in the same manner as energy cell 10 , and may be used in the same types of applications, as desired.
[0019] Referring now to FIGS. 3 and 4 , the energy cell 10 is shown in two specific applications for purposes of illustration. In FIG. 3 , two energy cells 10 A and 10 B, are mounted to the surface of a printed circuit board 36 having a variety of electrical components contained in discrete circuits 38 and 40 . The circuit 38 is schematically shown as being connected to and powered by the energy cell 10 A, whereas circuit 40 is powered by energy cell 10 B.
[0020] In FIG. 4 , a printed wiring board 41 is shown having a number of layers 42 stacked one on top of the other and multiple ground vias 44 . A number of discrete energy cells 10 are embedded at selected locations throughout the thickness of the board 41 to provide power for various electrical components carried by the board 41 . Lower energy x-ray bands charge the upper layers 42 of the stack, and higher energy x-ray bands penetrate to charge the lower layers 42 . It is contemplated that the higher energy x-ray bands will be partially absorbed by the upper layers 42 , which reduces their band energy and therefore increases the IEMF charge on the lower layers 42 of the stack. One circuit 46 is shown at the top layer 48 of the board 41 connected by a lead 50 to one or more energy cells 10 . A number of independent circuits or individual electrical components (not shown) may be located within a housing 52 which is schematically depicted at the base of the board 41 . A separate lead 56 may be extended between each of such components or circuits and discrete energy cells 10 , as shown.
[0021] As noted above, factors such as the physical size of the plates 12 , 14 (or wire 28 and sheath 30 ), the duration of their exposure to high energy photons and whether more than one energy cell 10 or 26 are connected together can affect the total electrical energy produced. In one example, a 1 mil thick gold plate having length and width dimensions of 1 inch by 1 inch, and a 1 mil thick aluminum plate with the same dimensions were placed on either side of a 1.5 mil thick section of fiberglass dielectric material and irradiated with x-rays. A 42 Rad (Si) dose of x-rays applied to this test sample for a period of 0.5 minutes resulted in a voltage of about 0.57 volts, a 168 Rad (Si) dose applied to such sample for a period of 2 minutes produced a voltage of about 0.8 volts, and, a 294 Rad (Si) dose applied to the sample for a period of about 3.5 minutes produced a voltage of about 1.18 volts. Testing and software simulations indicate that about 39% of the x-ray energy applied to the energy cell example noted above was “harvested” in the form of an IEMF charge. It is contemplated that levels of electrical energy suitable for a wide variety of applications can be produced by the energy cells 10 or 24 of this invention, when used either as a source of energy or a detector of the presence of high energy photon irradiation.
[0022] While the invention has been described with reference to a preferred embodiment, it should be understood by those skilled in the art that various changes may be made and equivalents substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims. | An energy cell, employed as a passive energy source, takes advantage of the differing electrical properties of metals to produce an induced electromagnetic force charge when exposed to dosages of high energy photons such as x-ray or gamma rays. | 7 |
RELATED APPLICATION DATA
[0001] This application is a continuation of U.S. patent application Ser. No. 13/494,849, filed Jun. 12, 2012 (now U.S. Pat. No. 8,660,298), which is a continuation of U.S. patent application Ser. No. 12/634,505, filed Dec. 9, 2009 (now U.S. Pat. No. 8,199,969), which is a continuation-in-part of U.S. patent application Ser. No. 12/337,029, filed Dec. 17, 2008 (published as US 2010-0150434 A1). The above patent documents are each hereby incorporated herein by reference in its entirety.
TECHNICAL FIELD
[0002] The present invention relates generally to steganographic data hiding and digital watermarking.
BACKGROUND AND SUMMARY
[0003] The term “steganography” generally means data hiding. One form of data hiding is digital watermarking. Digital watermarking is a process for modifying media content to embed a machine-readable (or machine-detectable) signal or code into the media content. For the purposes of this application, the data may be modified such that the embedded code or signal is imperceptible or nearly imperceptible to a user, yet may be detected through an automated detection process. Most commonly, digital watermarking is applied to media content such as images, audio signals, and video signals.
[0004] Digital watermarking systems may include two primary components: an embedding component that embeds a watermark in media content, and a reading component that detects and reads an embedded watermark. The embedding component (or “embedder” or “encoder”) may embed a watermark by altering data samples representing the media content in the spatial, temporal or some other domain (e.g., Fourier, Discrete Cosine or Wavelet transform domains). The reading component (or “reader” or “decoder”) analyzes target content to detect whether a watermark is present. In applications where the watermark encodes information (e.g., a message or payload), the reader may extract this information from a detected watermark.
[0005] A watermark embedding process may convert a message, signal or payload into a watermark signal. The embedding process then combines the watermark signal with media content and possibly another signals (e.g., an orientation pattern or synchronization signal) to create watermarked media content. The process of combining the watermark signal with the media content may be a linear or non-linear function. The watermark signal may be applied by modulating or altering signal samples in a spatial, temporal or some other transform domain.
[0006] A watermark encoder may analyze and selectively adjust media content to give it attributes that correspond to the desired message symbol or symbols to be encoded. There are many signal attributes that may encode a message symbol, such as a positive or negative polarity of signal samples or a set of samples, a given parity (odd or even), a given difference value or polarity of the difference between signal samples (e.g., a difference between selected spatial intensity values or transform coefficients), a given distance value between watermarks, a given phase or phase offset between different watermark components, a modulation of the phase of the host signal, a modulation of frequency coefficients of the host signal, a given frequency pattern, a given quantizer (e.g., in Quantization Index Modulation) etc.
[0007] The present assignee's work in steganography, data hiding and digital watermarking is reflected, e.g., in U.S. Pat. Nos. 6,947,571; 6,912,295; 6,891,959. 6,763,123; 6,718,046; 6,614,914; 6,590,996; 6,408,082; 6,122,403 and 5,862,260, and in published specifications WO 9953428 and WO 0007356 (corresponding to U.S. Pat. Nos. 6,449,377 and 6,345,104). Each of these patent documents is hereby incorporated by reference herein in its entirety. Of course, a great many other approaches are familiar to those skilled in the art. The artisan is presumed to be familiar with a full range of literature concerning steganography, data hiding and digital watermarking.
[0008] One possible combination of the disclosed technology is a method including: receiving a color image or video; transforming the color image or video signal by separating the color image or video into at least first data representing a first color channel of the color image or video and second data representing a second color channel of the color image or video, where the first data comprises a digital watermark signal embedded therein and the second data comprises the digital watermark signal embedded therein with a signal polarity that is inversely related to the polarity of the digital watermark signal in the first data; subtracting the second data from the first data to yield third data; using at least a processor or electronic processing circuitry, analyzing the third data to detect the digital watermark signal; once detected, providing information associated with the digital watermark signal.
[0009] Another combination is a method including: obtaining first data representing a first chrominance channel of a color image or video, where the first data comprises a watermark signal embedded therein; obtaining second data representing a second chrominance channel of the color image or video, the second data comprising the watermark signal embedded therein but with a signal polarity that is inversely related to the polarity of the watermark signal in the first data; combining the second data with the first data in manner that reduces image or video interference relative to the watermark signal, said act of combining yielding third data; using at least a processor or electronic processing circuitry, processing the third data to obtain the watermark signal; once obtained, providing information associated with the watermark signal.
[0010] Still another combination is an apparatus comprising: a processor or electronic processing circuitry to control: (a) handling of first data representing a first color channel of a color image or video, where the first data comprises a watermark signal embedded therein; (b) handling of second data representing a second color channel of the color image or video, the second data comprising the watermark signal embedded therein but with a signal polarity that is inversely related to the polarity of the watermark signal in the first data; (c) combining the second data with the first data in manner that reduces image or video interference relative to the watermark signal, the combining yielding third data; (d) processing the third data to obtain the watermark signal; and (e) once obtained, providing information associated with the watermark signal.
[0011] Yet another possible combination is a method including: a method including: obtaining first data representing a first chrominance channel of a color image or video signal; obtaining second data representing a second chrominance channel of the color image or video signal; using a processor or electronic processing circuitry, embedding a watermark signal in the first data with a first signal polarity; using a processor or electronic processing circuitry, transforming the second data by embedding the watermark signal in the second data so that when embedded in the second data the watermark signal comprises a second signal polarity that is inversely related to the first signal polarity of the watermark signal in the first data; combining the watermarked first data and the watermarked second data to yield a watermarked version of the color image or video signal, whereby during detection of the watermark signal from the watermarked version of the color image or video signal, the second data is combined with the first data in a manner that reduces image or video signal interference relative to the watermark signal.
[0012] Further combinations, aspects, features and advantages will become even more apparent with reference to the following detailed description and accompanying drawing.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 represents a color image.
[0014] FIG. 2 represents a first color channel (‘a’ channel) of the color image representation shown in FIG. 1 .
[0015] FIG. 3 represents a second color channel (‘b’ channel) of the color image representation shown in FIG. 1 .
[0016] FIG. 4 is a representation of the sum of the first color channel of FIG. 2 and the second color channel of FIG. 3 (e.g., a+b).
[0017] FIG. 5 is a graph showing a histogram standard deviation of FIG. 4 .
[0018] FIG. 6 is a representation of the difference between the first color channel of FIG. 2 and the second color channel of FIG. 3 (a−b).
[0019] FIG. 7 is a graph showing a histogram standard deviation of FIG. 6 .
[0020] FIG. 8 is an image representation of the difference between the first color channel of FIG. 2 (including a watermark signal embedded therein) and the second color channel of FIG. 3 (including the watermark signal embedded therein).
[0021] FIG. 9 is a graph showing a histogram standard deviation of FIG. 8 .
[0022] FIGS. 10 a and 10 b are block diagrams showing, respectively, an embedding process and a detection process.
[0023] FIG. 11 is a diagram showing watermarks embedded in first and second video frames.
DETAILED DESCRIPTION
[0024] The following disclosure discusses a digital watermarking technique that utilizes at least two chrominance channels (also called “color planes,” “color channels” and/or “color direction”). Chrominance is generally understood to include information, data or signals representing color components of an image or video. In contrast to a color image or video, a grayscale (monochrome) image or video has a chrominance value of zero.
[0025] Media content that includes a color image (or color video) is represented in FIG. 1 . An industry standard luminance and chrominance color space is called “Lab” (for Lightness (or luminance), plus ‘a’ and ‘b’ color channels) that can be used to separate components of images and video. FIG. 2 is an ‘a’ channel representation of FIG. 1 (shown in grayscale), and FIG. 3 is a ‘b’ channel representation of FIG. 1 (shown in grayscale). Of course, our inventive methods and apparatus will apply to and work with other color schemes and techniques as well. For example, alternative luminance and chrominance color schemes include “Yuv” (Y=luma, and ‘u’ and ‘v’ represent chrominance channels) and “Ycc.” (also a dual chrominance space representation).
[0026] Let's first discuss the additive and subtractive effects on FIGS. 2 and 3 . FIG. 4 illustrates a representation of the result of adding the ‘a’ channel ( FIG. 2 ) with the ‘b’ channel ( FIG. 3 ). FIG. 6 illustrates a representation of the result of subtracting the ‘b’ channel ( FIG. 3 ) from the ‘a’ channel ( FIG. 2 ). The result of subtracting the ‘b’ channel from the ‘a’ channel yields reduced image content relative to adding the two channels since the ‘a’ and ‘b’ color planes have correlated image data in the Lab scheme. (In typical natural imagery, the ‘a’ and ‘b’ chrominance channels tend to be correlated. That is to say where ‘a’ increases, ‘b’ also tends to increase. One measure of this is to measure the histogram of the two chrominance planes when they are added (see FIG. 5 ), and compare that to the histogram when the two color planes are subtracted (see FIG. 7 ). The fact that the standard deviation of FIG. 7 is about half that of FIG. 5 also supports this conclusion, and illustrates the reduction in image content when ‘b’ is subtracted from ‘a’) In this regard, FIG. 4 provides enhanced or emphasized image content due to the correlation. Said another way, the subtraction of the FIG. 3 image from FIG. 2 image provides less image interference or reduces image content. The histogram representations of FIG. 4 and FIG. 6 (shown in FIGS. 5 and 7 , respectively) further support this conclusion.
[0027] Now let's consider watermarking in the context of FIGS. 2 and 3 .
[0028] In a case where a media signal includes (or may be broken into) at least two chrominance channels, a watermark embedder may insert digital watermarking in both the ‘a’ color direction ( FIG. 2 ) and ‘b’ color direction ( FIG. 3 ). This embedding can be preformed in parallel (if using two or more encoders) or serial (if using one encoder). The watermark embedder may vary the gain (or signal strength) of the watermark signal in the ‘a’ and ‘b’ channel to achieve improved hiding of the watermark signal. For example, the ‘a’ channel may have a watermark signal embedded with signal strength that greater or less than the watermark signal in the ‘b’ channel. Alternatively, the watermark signal may be embedded with the same strength in both the ‘a’ and ‘b’ channels. Regardless of the watermark embedding strength, watermark signal polarity is preferably inverted in the ‘b’ color plane relative to the ‘a’ color plane. The inverted signal polarity is represented by a minus (“−”) sign in equations 1 and 2.
[0000] WM a=a (channel)+wm (1)
[0000] WM b=b (channel)−wm (2)
[0029] WMa is a watermarked ‘a’ channel, WMb is a watermarked ‘b’ channel, and wm represents a watermark signal. A watermarked color image (including L and WMb and WMa) can be provided, e.g., for printing, digital transfer or viewing.
[0030] An embedded color image is obtained (from optical scan data, memory, transmission channel, etc.), and data representing the color image is communicated to a watermark detector for analysis. The detector (or a process, processor or electronic processing circuitry used in conjunction with the detector) subtracts WMb from WMa resulting in WMres as shown below:
[0000] WMres=WM a −WM b (3)
[0000] WMres=( a +wm)−( b −wm) (4)
[0000] WMres=( a−b )+2*wm (5)
[0031] This subtraction operation yields reduced image content (e.g., FIG. 6 ) as discussed above. The subtraction or inverting operation of the color channels also emphasizes or increases the watermark signal (2*wm), producing a stronger watermark signal for watermark detection. Indeed, subtracting the color channels increases the watermark signal-to-media content ratio: WMres=(a−b)+2*wm.
[0032] FIG. 8 illustrates the result of equation 5 (with respect to watermarked versions of FIG. 2 and FIG. 3 ). As shown, the perceptual “graininess” or “noise” in the image corresponds to the emphasized watermark signal. The image content is also reduced in FIG. 8 . A histogram representation of FIG. 8 is shown in FIG. 9 and illustrates a favorable reduction of image content.
[0033] A watermark detector may extract or utilize characteristics associated with a synchronization signal (if present) from a frequency domain representation of WMres. The detector may then use this synchronization signal to resolve scale, orientation, and origin of the watermark signal. The detector may then detect the watermark signal and obtain any message or payload carried thereby.
[0034] To even further illustrate the effects of improving the watermark signal-to-media content ratio with our inventive processes and systems, we provide some additive and subtractive examples in the content of watermarking.
[0035] For the following example, a watermark signal with the same polarity is embedded in each of the ‘a’ color channel and the ‘b’ color channel. The same signal polarity is represented by a plus (“+”) sign in equations 6 and 7.
[0000] WM a=a +wm (6)
[0000] WM b=b +wm (7)
[0036] WMa is a watermarked ‘a’ channel, WMb is a watermarked ‘b’ channel, and wm represents a watermark signal. A watermarked color image (including L and WMb and WMa) can be provided, e.g., for printing, digital transfer or viewing.
[0037] An embedded color image is obtained, and data representing the color image is communicated to a watermarked detector for analysis. The detector (or a process, processor, or electronic processing circuitry used in conjunction with the detector) adds the ‘a’ and ‘b’ color channels to one another (resulting in WMres) as shown below:
[0000] WMres=WM a +WM b (8)
[0000] WMres=( a +wm)+( b +wm) (9)
[0000] WMres=( a+b )+2*wm (10)
[0038] This addition operation results in increased image content (e.g., FIG. 4 ). Indeed, image interference during watermark detection will be greater since the two correlated ‘a’ and ‘b’ color channels tend to reinforce each other.
[0039] By way of further example, if WMb is subtracted from WMa (with watermark signals having the same polarity), the following results:
[0000] WMres=WM a −WM b (11)
[0000] WMres=( a +wm)−( b +wm) (12)
[0000] WMres=( a−b )+≈0*wm (13)
[0040] A subtraction or inverting operation in a case where a watermark signal includes the same polarity decreases image content (e.g., FIG. 4 ), but also significantly decreases the watermark signal. This may result in poor—if any—watermark detection.
[0041] FIGS. 10 a and 10 b are flow diagrams illustrating some related processes and methods. These processes may be carried out, e.g., via a computer processor, electronic processing circuitry, printer, handheld device such as a smart cell phone, etc.
[0042] With reference to FIG. 10 a , a color image (or video) is obtained and separated into at least two (2) color channels or planes ( 10 ). A watermark signal is determined for the color image or video ( 12 ). Of course, the watermark signal for the color image or video may be determined prior to or after color plane separation. The determined watermark signal is embedded in a first of the color planes ( 14 ). An inverse polarity version of the watermark signal is embedded in a second color plane. The color planes are recombined (perhaps with data representing luminance) to form a composite color image.
[0043] With reference to FIG. 10 b , a watermarked color image or video is obtained or received ( 11 ). The color image (or video) has or can be separated into at least two (2) color planes or channels ( 13 ). A first color plane includes a watermark signal embedded therein. A second color plane includes the watermark signal embedded therein with a polarity that is inversely related to the watermark signal in the first color plane. The watermarked second color plane is subtracted from the watermarked first color ( 15 ). The result of the subtraction is analyzed to detect the watermark signal. A detected watermark message, signal or payload can be provided ( 19 ), e.g., to a remote database to obtain related metadata or information, to a local processor, for display, to a rights management system, to facilitate an online transaction, etc.
[0044] In addition to the Lab color scheme discussed above, a watermark signal may be embedded in color image (or video) data represented by RGB, Yuv, Ycc, CMYK or other color schemes, with, e.g., a watermark signal inserted in a first chrominance direction (e.g., red/green direction, similar to that discussed above for the ‘a’ channel) and a second chrominance direction (e.g., a blue/yellow direction, similar to that discussed above for the ‘b’ channel). For watermark signal detection with an alterative color space, e.g., an RGB or CMYK color space, an image can be converted to Lab (or other color space), or appropriate weights of, e.g., RGB or CMY channels, can be used. For example, the following RGB weights may be used to calculate ‘a’−‘b’: Chrominance Difference=0.35*R−1.05*G+0.70*B+128, where R, G and B are 8-bit integers.
[0045] Further Considerations of Video
[0046] The human contrast sensitivity function curve shape with temporal frequency (e.g., relative to time) has a very similar shape to the contrast sensitivity with spatial frequency.
[0047] Successive frames in a video are typically cycled at about at least 60 Hz to avoid objectionable visual flicker. So-called “flicker” is due to the high sensitivity of the human visual system (HVS) to high temporal frequency changes in luminance. The human eye is about ten (10) times less sensitive to high temporal frequency chrominance changes.
[0048] Consider a video sequence with frames as shown in FIG. 11 . A chrominance watermark can be added to frame 1 per the above description for images. In a similar way, a watermark is added to frame 2 but the polarity is inverted as shown in FIG. 11 .
[0049] In order to recover the watermark, pairs of frames are processed by a watermark detector, and the ‘a’ channels are subtracted from each other as shown below.
[0000] Det — a =( a 1+wm)−( a 2−wm)=( a 1− a 2)+2*wm (14)
[0050] Det_a refers to watermark detection processing of the ‘a’ channel. Because of the temporal correlation between frames, the image content in equation 14 is reduced while the watermark signal is reinforced.
[0000] In a similar way the ‘b’ channels are also subtracted from each other
[0000] Det — b =( b 1−wm)−( b 2+wm)=( b 1− b 2)−2*wm (15)
[0051] Det_a refers to watermark detection processing of the ‘b’ channel. Equation 14 and 15 are then subtracted from each other as shown below in equation 16.
[0000]
Det_a
-
Det_b
=
(
a
1
-
a
2
+
2
*
wm
)
-
(
b
1
-
b
2
-
2
*
wm
)
=
(
a
1
-
a
2
)
-
(
b
1
-
b
2
)
+
4
*
wm
(
16
)
[0052] In generally, related (but not necessarily immediately adjacent) frames will have spatially correlated content. Because of the spatial correlation between the ‘a’ and ‘b’ frames, the image content is reduced while the watermark signal is reinforced. See equation 16.
[0053] For any one pair of frames selected by a watermark detector, the polarity of the watermark could be either positive or negative. To allow for this, the watermark detector may examine both polarities.
Concluding Remarks
[0054] Having described and illustrated the principles of the technology with reference to specific implementations, it will be recognized that the technology can be implemented in many other, different, forms. To provide a comprehensive disclosure without unduly lengthening the specification, applicant hereby incorporates by reference each of the above referenced patent documents in its entirety.
[0055] The methods, processes, components, apparatus and systems described above may be implemented in hardware, software or a combination of hardware and software. For example, the watermark encoding processes and embedders may be implemented in software, firmware, hardware, combinations of software, firmware and hardware, a programmable computer, electronic processing circuitry, and/or by executing software or instructions with a processor or circuitry. Similarly, watermark data decoding or decoders may be implemented in software, firmware, hardware, combinations of software, firmware and hardware, a programmable computer, electronic processing circuitry, and/or by executing software or instructions with a processor, parallel processors or other multi-processor configurations.
[0056] The methods and processes described above (e.g., watermark embedders and detectors) also may be implemented in software programs (e.g., written in C, C++, Visual Basic, Java, Python, Tcl, Perl, Scheme, Ruby, executable binary files, etc.) stored in memory (e.g., a computer readable medium, such as an electronic, optical or magnetic storage device) and executed by a processor (or electronic processing circuitry, hardware, digital circuit, etc.).
[0057] While one embodiment discusses inverting the polarity in a second color channel (e.g., a ‘b’ channel), one could also invert the polarity in the first color channel (e.g., an ‘a’ channel) instead. In such a case, the first color channel is then preferably subtracted from the second color channel.
[0058] The particular combinations of elements and features in the above-detailed embodiments are exemplary only; the interchanging and substitution of these teachings with other teachings in this and the incorporated-by-reference patents are also contemplated. | The present disclosure relates generally signal processing. One claim recites an apparatus comprising: memory for storing a color video signal comprising first data and second data; and a processor. The processor is programmed for: modifying first color information and second color information of the first data by encoding a signal in the first color information such that the signal includes a first signal polarity, and encoding the signal in the second color information such that signal includes a second signal polarity that is inversely related to the first signal polarity, and modifying first color information and second color information of the second data by encoding the signal in the first color information such that signal includes the second signal polarity, and encoding the signal in the second color information such that the signal includes the first signal polarity. Of course, different combinations and claims are provided too. | 7 |
FIELD OF INVENTION
[0001] The present invention is related to collapsible toy structures such as tents and playhouses.
BACKGROUND OF INVENTION
[0002] Collapsible structures that are used for playhouses are well-known in the art. They are typically collapsible into a small volume but can be easily popped up by various means, including the use of extendable frames and inflatable tubes. U.S. Pat. No. 6,305,396 described a collapsible structure that is provided with a plurality of foldable frame members each having a folded and an unfolded orientation. A fabric material is provided for covering a portion of each frame member to form a side panel therefrom. The structure may be folded and stored by folding the side panels and their corresponding frame members on top of each other about the hinge portions to have the side panels and frame members overlying each other. The overlying side panels and frame members are then collapsed by twisting and folding to form a plurality of concentric frame members to substantially reduce the size of the structure.
[0003] The above described structure has many advantages, but has the limitation of not being able to create structures with irregular sides or unusual shapes. One solution to this problem is provided by the Airmaze air play tent that uses a fan to blow the enclosure open. The fan, however, obviously poses a hazard, especially to small children. It is therefore an object to have present invention to provide improved collapsible structures.
SUMMARY OF INVENTION
[0004] Accordingly, the present invention provides a foldable enclosure structure containing a fabric cover defining a desired shape when expanded to an expanded position; a first supporting frame attached to the cover; and a second supporting frame provided within the cover and rotatably coupled to the first frame such that the second frame is movable between a collapsed position and an expanded position. According to the structure of the instant invention, the second frame is superposed over the first frame in the collapsed position for ease of storage, but is rotated axially to intersect with the first frame in the expanded position to prop up the cover to the desired shape. To ensure that the structure is stable in the expanded position, fixing means are provided for fixedly attaching the second frame to the first frame in the expanded position.
[0005] In the preferred embodiment, the shape of the two frames assume the same shape as the cross-sectional shape of the cover along the points to which they attach such that they effectively prop up the cover in the expanded position.
[0006] In another embodiment, the first and second frames are both fixedly sewn onto the cover. The frames may be sewn either onto the inner or outer sides of the cover. The intersections between the first and second frames are left unsewn, such that the two frames can rotate axially relative to each other.
[0007] In another preferred embodiment, the first and second frames are each foldable from an open position to a folded position, the folded position achievable by twisting and folding the frames into at least two concentric circles. Since the two frames are superimposed onto each other in the collapsed position, it is most convenient for the user to twist and fold the two frames together simultaneously. This would reduce the total area of the collapsed structure to a minimum.
[0008] In one specific embodiment of a toy house, the first and second frames are each in the general shape of a loop and containing a first and second central vertical axis respectively. The first and second frames are coupled together such that the first and second central vertical axes coincide with each other, and the second frame rotatable therealong. In this embodiment, the two loops may be coupled theretogether by an elastic band provided at the top intersection between the frames. In another preferred embodiment, the fixing means is a set of Velcro tapes that allow the two frames to be fixedly attached theretogether after the second frame has been rotated to the expanded position.
[0009] In another embodiment, the fixing means is a bottom pad for mounting onto the bottom of the enclosure. This bottom pad has a bottom frame shaped to match the shape of the bottom of the desired shape for abutment of the first and second frame in the expanded position.
[0010] Near the top of the structure, at least one reinforcement frame may further be attachable along the girth of the first and second frames in the expanded position to prop up the cover to the desired shape. This reinforcement frame is preferably attached to the first and second frames after they are arranged into the expanded position.
[0011] In another preferred embodiment, the cover defines a complete enclosure with a top portion, a bottom portion and side portions for sheltering at least one person therein, the cover further provided with at least one opening for the person to access therethrough.
[0012] In another embodiment, the first and second frames are each in the general shape of a loop with a first and second central horizontal axis respectively. The first and second frames are coupled together such that the first and second central horizontal axes coincide with each other, and the second frame rotatable therealong. This embodiment is suitable for shapes such as aeroplanes and airships. In the preferred embodiment, the fixing means is at least one loop attachable to the first and second frames along the vertical girth for abutment in the expanded position.
[0013] In another aspect of the present invention, a method of supporting a fabric enclosure is provided comprising providing a plurality of rigid or semi-rigid loops having a shape of a section of the enclosure and defining a central axis therein; fixedly attaching one of the loop to a cross-section of the enclosure; and coupling the other loop or loops to the attached loop at a position wherein the loop or loops are rotatable along the central axis relative to the attached loop. In the preferred method, the loops in pre-determined relative position are abutted into position using a reinforcement frame.
[0014] Using the teaching provided herein, many different structures with various shapes may be made. The structures may be expanded to huge enclosures, but readily collapsible into a very small package of concentric circles for ease of handling and storage. The time and skills required to construct the structure is nominal, since it is capable of expanding upon release, and the loops are coupled together such that they only need to be rotated into the appropriate expanded position, and the fixing means attached.
BRIEF DESCRIPTION OF DRAWINGS
[0015] FIG. 1A is a drawing of an exploded view of the supporting structures according to one embodiment of the present invention. The fabric cover is not shown for ease of understanding.
[0016] FIG. 1B shows the assembled supporting structures according to the same embodiment as FIG. 1A . The fabric cover is not shown.
[0017] FIG. 1C shows the perspective view of the fully expanded cover of the enclosure structure according to the same embodiment as FIG. 1A with windows and openings that can be provided on the cover.
[0018] FIG. 1D shows the step of the folding process for a frame into three concentric loops.
[0019] FIG. 2A shows a second embodiment according to the present invention in which a first, second and third frames are rotatable along a horizontal axis in an expanded position.
[0020] FIG. 2B shows an additional reinforcement loop provided within the structure shown in FIG. 2A .
[0021] FIGS. 2C and 2D shows a second and third reinforcement loop provided respectively within the structure shown in FIG. 2B .
[0022] FIG. 3 shows a third embodiment of the present invention in which additional structures are provided.
DETAILED DESCRIPTION
[0023] In the following description and in the claims, the term “fabric” is simply used to describe a material that has the collapsible and foldable characteristics of a fabric, and is not meant to limit the instant invention to any particular type of material. The cover may be made of, among other things, nylon, cotton, leather, PVC and other natural, synthetic or blended material. The term “loop” is defined loosely as any rigid or semi-rigid frame that forms a complete piece without any break in the frame. The “loop” may be of any shape, such as circular, triangular, quadrilateral, polylateral, mushroom, or any other regular or irregular shape. A “semi-rigid” frame has the characteristic of maintaining a defined shape when it is expanded into the fully open position, but can also be folded, or twisted into concentric circles, or otherwise collapsible by other ways.
[0024] Referring to FIGS. 1A to 1 C, the first embodiment exemplifying the present invention shows two identical frames 22 and 24 that have a mushroom-like shape in the fully open position. A fabric enclosure assuming the shape of a mushroom with a dome-shaped top 23 a and a short, thick stem at the bottom 23 b (see FIG. 1C ). The bottom portion of the stem is also shown to have a girth that spreads wider than the top portion of the stem. For ease of illustration, only FIG. 1C shows the fabric enclosure or cover, and the relative position of the same cover is only shown as dotted lines in FIG. 1A . The two frames in the open position assumes a shape that is the same as the cross-sectional shape of the cover (i.e. a mushroom shape in this example) along which they should propping up in the expanded position. In the most preferred embodiment, the first frame 22 is sewn and fixed onto the appropriate position along the cover. The first frame is sewn on the inside of the cover. In the operating position, the two frames are provided in the upright position, each with a central vertical axis defined therein (in FIG. 1A , the two frames are positioned such that their central axes coincide along line 26 ). In this embodiment, the second frame is also be fixedly sewn onto the inside of the cover, except that the points of intersection 28 and 30 with the first frame are not sewn to the cover, such that the two frames may rotate axially relative to each other as shown by arrow 40 . In this embodiment, first and second frames may be sewn either on the outside or the inside of the cover, and are considered “rotatably coupled” with the cover itself acting as the coupling means.
[0025] In this example, the frames are arranged such that they are axially aligned along the vertical axis and, when the frames are in the expanded position, intersect at a 90 degree angle. In this embodiment, three optional reinforcement loops 32 , 34 and 36 of varying sizes, and a square pad 38 with a semi-rigid frame is also provided. Pad 38 assumes the same shape as defined by the bottom of the two frames, and once it is inserted into the enclosure as shown in FIG. 1B , the two frames would be secured at a 90 degree angle. The three reinforcement loops can then be attached along various heights of the girth of the top portion of the mushroom structure, for example by velcro tapes provided at the appropriate position. The cover 25 as shown in FIG. 1C also illustrates how windows 25 a and openings 25 b may be provided.
[0026] When a user wants to store the mushroom in a small package, the semi-rigid detachable reinforcement loops 32 , 34 and 36 and the pad 38 are removed. Frame 24 is then rotated according to general direction shown by arrow 40 such that frame 22 and 24 are superimposed one next to another. Due to the soft, foldable nature of the cover, the frames are readily rotatable and foldable even if they are fixedly sewn onto the cover. They can then be twisted into three concentric circles, and the fabric of the cover, still attached to frame 22 , would collapse together with the frames. The three reinforcement loops and the pad can also be twisted and folded into smaller concentric loops for ease of storage. The way one of the loops may be folded is shown in FIG. 1D . Although only one loop is shown in FIG. 1D , it is understandable that all the semi-rigid loops can be folded up in the same manner as illustrated in FIG. 1D .
[0027] Referring now to FIG. 2A to 2 C, another embodiment of the present invention is shown in the form of a generally olive-shaped space ship. In this example, there are three identical frames 42 , 44 and 46 provided within a fabric cover or enclosure that has a general olive shape lying on its side under normal usage. For ease of illustration, the fabric cover is not shown in order to review the supporting structures therein. It is understood that openings may be provided in the enclosure for a user such as a child to enter the space ship and reside within the confines of the frames. Frame 42 is fixedly sewn onto the inner side of the cover, and frames 44 and 46 are rotatably coupled thereto using an elastic band attached to the cover at the two side ends 48 and 50 of the spaceship such that frames 44 and 46 are rotatable along a horizontal axis 52 that also coincides with their respective longitudinal axis of symmetry. In the expanded position as shown, the three frames intersect each other at an angle of 60 degrees.
[0028] FIG. 2B shows one large reinforcement loop 54 provided at one end of the olive-shaped structure and aligned perpendicularly to the axis 52 . For ease of description, this vertical alignment of the reinforcement loop relative to the horizontal axis of rotation is referred to as attachment of the reinforcement loop to the vertical girth of the frames. Fixing means such as Velcro tapes are provided at the relevant position of the inner side of the enclosure for the secure position thereof. In the specific example, the reinforcement loop 54 assumes a curved shape 54 a along ¾ of sides, but contains on flat side 54 b which is preferably facing the floor to stabilize the entire spaceship structure.
[0029] FIGS. 2C and 2D shows two further reinforcement loops 56 and 58 provided at the mid-section and right-end section of the space ship. Again, Velcro tapes are provided along the designated positions of the inner side of the cover for fixed attachment thereto. Again, the bottom side of these two reinforcement loops are flat to provide stability to the whole structure.
[0030] When a user wishes to store the spaceship in a small package, the three reinforcement loops may again be detached and the three frames 42 , 44 and 46 be rotated to superimpose on each other in the collapsed form. If the three frames are large, and made of a semi-rigid material, they can be further twisted and folded simultaneously each into two or three concentric circles for storage. The three frames will stay within the fabric of the cover, and they are attached or coupled to the inner side thereof, and therefore the entire structure would conveniently be stored. The three reinforcement frames may also be twisted and folded and put in the same small bag for storage.
[0031] FIG. 3 shows another embodiment in which the basic enclosure or cover is a cube 60 , supported by two square frames 62 and 64 . One optional square reinforcement frames 66 and one optional abutment frame 68 are also provided at the top and bottom respectively of the enclosure, and fixed thereto by fixing means such as Velcro tapes. An opening 70 is provided on the cover for a user to access the interior. Windows 70 a are also provided. In this example, four additional conical/cylindrical structures 72 are provided at the four corners to give the structure the appearance of a castle. The structures 72 are simply attached onto the expanded cover using velcro tape as illustrated in the shaped area 74 . For ease of illustration, only one of the four areas is shaped so as not to obscure the other structures.
[0032] Although the above example has been described generally with two or three identically shaped frames or loops, the present invention may clearly be practised with more than two loops. For example, this may be a substitution for the reinforcement frames in the larger enclosures. In such a case, the loops may be, for example, spread evenly at 60 degree angles into three evenly distributed frames. The bottom pad, if desired, may be a hexagon.
[0033] While the present invention has been described with particular reference to the aforementioned figures, it is understood that the figures are for illustration only, and the instant invention is not limited thereto. It is intended that the scope of the present invention be defined by the claims appended herewith, and include many variations and embodiments not specifically described herein. For example, the intersection of the frames in the examples are described as having 60 or 90 degree angles, but it is clear that, depending on the shape and size of the enclosure, the absence or presence of the optional reinforcement frames and other abutment means etc would affect the number and arrangement of the frames used for the fully expanded position. Furthermore, one of the fixing means are described as bottom pad or velcro tapes, but it is clear that other fixing means, such as zippers, tying cloth or string, button etc may also be used. The coupling means as described in the first example actually uses the cover therefor, with the two frames fixed thereto except at the points of intersection, while elastic band is described as the coupling means in the second example. Many other alternative arrangements may be used. For example, strings and mechanical joints may also be used. | A foldable enclosure structure containing a fabric cover defining a desired shape when expanded to an expanded position; a first supporting frame fixedly attached to the cover and a second supporting frame provided within the cover and rotatably coupled to the first frame such that the second frame is movable between a collapsed position and an expanded position. The second frame is superposed over the first frame in the collapsed position for ease of storage, but is rotated axially to intersect with the first frame in the expanded position to prop up the cover to the desired shape. To ensure that the structure is stable in the expanded position, fixing means is/are provided for fixedly attaching the second frame to the first frame in the expanded position. | 4 |
FIELD OF THE INVENTION
The present invention is concerned with etching apertures having well defined crystallographic geometries in single crystals and particularly in such materials as aluminum oxides including its sapphire form, spinels such as magnesium aluminum spinel and garnets such as yttrium aluminum garnet, and yttrium iron garnet.
BACKGROUND OF THE INVENTION
Substrates of hard and relatively passive materials such as sapphire, magnesium aluminum spinel, yttrium aluminum garnet (YAG), and yttrium iron garnet (YIG) with at least one aperture therein having well defined crystallographic geometry are of interest in view of their applicability as fluid spray nozzles for magnetic and electrostatic jet printing applications, and other gas or liquid metering and filtering systems requiring calibrated single or multiple orifices. Likewise, such substrates having a pattern of a plurality of apertures may be useful as substrates for wiring and packaging integrated circuits and other solid state components, or as a filter or guide for electromagnetic radiation.
In ink jet printing applications, a jet of ink is forced through a vibrating nozzle causing the jet of ink to break up into droplets of substantially equal size. The printing is affected by controlling the flight of the droplets to a target such as paper. Important characteristics for ink jet printing applications are the size of respective nozzles, spacial distribution of the nozzles in an array, and the means for vibrating the respective nozzles. Such factors affect velocity uniformity of fluid emitted from the respective nozzles, directionality of the respective droplets, and break off distance of the individual droplets, that is, the distance between the exit of the nozzle and the position of the first droplet.
Accordingly, it is important that the methods for providing apertures in such substrates be capable of accurately controlling and reproducing the size and shape of the apertures. It is important that the process be capable of providing small apertures whereby the individual size thereof can be readily controlled. When it is desired to prepare an array of a plurality of apertures, it is important that the process be capable of providing uniform size and capable of providing the desired spacial distribution of the array of apertures. Accordingly, one convenient way to achieve the desired control in providing apertures in such substrates as sapphire, magnesium aluminum spinel, yttrium aluminum garnets, and yttrium iron garnets is by use of a chemical etchant which reliably, repeatedly, and uniformly provides apertures of a defined geometric crystallography under defined conditions in substrates having certain orientation.
However, it is quite difficult to find such etchants in view of the many competing characteristics which an etchant must possess to provide the desired substrate with a well defined crystallographic geometry as required by the present invention. For instance, the suitable etchant must be capable of uniformly attacking the top surface of the substrate being treated regardless of local variations in the composition or prior surface conditions so that material in the top surface is nonpreferentially removed. If the material were preferentially removed when applied to the top surface, a selective etching process would take place whereby the etchant might preferentially attack material, for example, in cracks and fissures.
Also, in order to provide the types of apertures required by the present invention, the etchant must attack the sidewalls of the aperture at a rate different than it attacks the surface portion as it etches its way down through the material. In other words, the etchant must be anisotropic with respect to the etch rate of the surface as compared to that of the sidewalls. Moreover, problems that may exist in selecting an etchant include the fact that a substance may be suitable for removing surface material smoothly as in etch polishing procedures but on the sidewalls, due to the different orientation, etches nonuniformally causing rough sidewalls.
The present invention provides a process for etching apertures in such difficult to etch materials as aluminum oxide (e.g., sapphire), magnesium aluminum spinel, yttrium aluminum garnet, and yttrium iron garnet whereby the apertures obtained are of a well defined crystallographic geometry. Moreover, the process of the present invention is readily carried out and does not require the extreme elevated temperatures and times required by previously suggested etchants for sapphire materials.
SUMMARY OF THE INVENTION
The present invention is related to a method for etching at least one aperture or hole having a well defined crystallographic geometry in a single crystal of a material such as aluminum oxide, spinels such as magnesium aluminum spinel, and garnets such as yttrium aluminum garnet, and yttrium iron garnet. The process includes providing a substrate of the single crystal to be etched, followed by providing a masking material on the substrate to protect predetermined portions of the substrate from being etched. The masking material must be resistant to etching or attack by mixtures of sulfuric acid and phosphoric acid at temperatures of up to about 325° C. In addition, the masking material must be adherent to the substrate being etched.
The substrate is then contacted with a mixture of sulfuric acid and phosphoric acid for a time sufficient to anisotropically etch through predetermined portions of the substrate not protected by the masking material to provide at least one aperture. The mixture employed contains a range varying from a ratio of nine parts sulfuric acid to one part phosphoric acid to a ratio of one part sulfuric acid to nine parts phosphoric acid by volume. The mixture is maintained at a temperature between about 200° and 325° C during the contacting.
The particular crystallographic geometry obtained will depend upon the orientation of the surface and the orientations of the sidewalls and, to some extent, upon the temperatures of the etching composition. For instance, as will be described in detail hereinafter, holes formed in the basal plane surfaces of sapphire having orientation (0001) are three sided which converge to a point at the bottom resulting in a substantially triangular hole. On the other hand, etching magnesium aluminum spinel having orientation (100) or yttrium aluminum garnet having orientation (100) or yttrium iron garnet having orientation (100) results in four sided pyramids which taper or converge to a square hole at the bottom similar to the type of geometric crystallography shown for the silicon substrate described in U.S. Pat. No. 3,921,916 to Bassous.
That the substrate to which the present invention is directed could be etched to provide such well defined crystallographic geometries employing the phosphoric acid-sulfuric acid etchants was not predictable from the prior art. The fact that mixtures of sulfuric and phosphoric acids are suitable for polishing sapphire and magnesium aluminum spinel surfaces (see U.S. Pat. No. 3,964,942 to Berkenblit et al, and Reisman et al, "The Chemical Polishing of Sapphire and MgAl Spinel", Journal Electrochemical Society Solid State Science, Volume 118, pages 1653-57 (1971) is not sufficient to be able to predict that the same acid mixtures will possess all of the necessary characteristics for forming holes having well defined crystallographic geometries.
In particular, the etch rates when a substrate is masked can differ and does differ significantly as compared to a nonselective etch polishing wherein the entire surface is exposed to the etchant. Moreover, there is no way to predict how the etchant will affect the sidewalls of the hole as it progresses down through the surface of the material being etched. Of course, the important relationship between the relative selectivity of the etching rates between the top surface and the sidewalls necessary to provide the tapering or converging type of geometry as achieved by the present invention cannot be predicted from mere disclosure of polishing.
Although the etchant is known to be nonselective with respect to the particular top surfaces of the sapphire or magnesium aluminum spinel, there is no suggestion that such would likewise be nonselective with respect to the orientations present on the sidewalls.
The ability to etch or dissolve such materials to which the present invention is directed is a very complex and empirical art. Along these lines, the article entitled "Crystal Growth", Volume 28 (1975), pages 157-61, "The Dissolution Forms of Single Crystal Spheres V Dissolution of α-Al 2 O 3 ", Seismayer et al is believed relevant.
The unpredictability of the action of a mixture of phosphoric and sulfuric acid being a suitable etchant is demonstrated by the fact that such mixture is suitable as a selective etchant for gadolinium gallium garnets as disclosed by O'Kane et al in Journal Electrochemical Society, "Solid State Science and Technology", Volume 120, No. 9, pages 1272-74, Crystal Growth and Characterization of Gadolinium Gallium Garnet. A nonselective type etch for the top surface is essential in providing the types of holes required by the present invention.
Other uses of mixtures of phosphoric acid and sulfuric acid which do not suggest their suitability for the type of process employed in the present invention can be found in U.S. Pat. Nos. 3,194,704, 3,260,660, and 3,715,249.
BRIEF DESCRIPTION OF DRAWINGS
FIGS. 1A-1D represent sequential cross-sectional views of a substrate processed by a process of the present invention.
FIGS. 2A-2D are magnified sequential photographs by interference contrast of a sapphire wafer having orientation (0001) treated according to the present invention.
FIGS. 3A-3C are magnified photographs by scanning electron microscope of a sapphire wafer having orientation (0001) treated according to the present invention.
FIG. 4 represents a top view of a substrate having orientation (100) processed in accordance with the present invention.
DESCRIPTION OF PREFERRED EMBODIMENTS
The single crystals to which the present invention is particularly suitable include those aluminum oxides having one of the following orientations (0001), (1123), (1100), (1124), (1120), and (0112), and particularly the sapphire form of aluminum oxide; and substrates having orientations (100) and (110) and particularly magnesium aluminum spinel and garnets such as yttrium aluminum garnet and yttrium iron garnet. The term "garnet" as used herein refers to crystals of a rare earth, a group III metal or iron, and oxygen.
The present invention is preferably carried out by treating the basal plane of sapphire having orientation (0001), yttrium aluminum garnet of orientation (100), magnesium aluminum spinel of orientation (100), or yttrium iron garnet of orientation (100). The basal plane is that plane perpendicular to the C axis. The most preferred substrate employed according to the present invention is sapphire particularly when the final article to be employed is an ink nozzle. Sapphire has previously been suggested for such purposes (e.g., see U.S. Pat. No. 3,823,408 to Gordon, III).
Suitable substrates to be employed in the present invention are readily available. For instance, wafers of highly mechanically polished sapphire (α-Al 2 O 3 ) and magnesium aluminum spinel (MgO.Al 2 O 3 ) are available from commercial sources.
For a discussion of a process sequence of the present invention, reference is made to FIGS. 1A-1D.
The process of the present invention is carried out by providing a coating of a masking material on the substrate 1. The masking material must be adherent to the substrate and must be capable of resisting etching by the mixture of phosphoric and sulfuric acid at elevated temperatures of up to about 325° C. It has been found, according to the present invention, that a good masking material and particularly for an aluminum oxide substrate such as sapphire, is obtained by first coating the substrate with a chromium layer 2. The coated substrate is then further coated with a metal of the platinum family and preferably with platinum or rhodium and most preferably with platinum.
The presence of the chromium layer 2 is important since it enhances the adhesion or adherence between the substrate and the layer 3 of the platinum family. As will be discussed hereinbelow, the coated substrate is heated to achieve a reaction between the metal of the platinum family and chromium thereby forming a layer containing platinum-type chromium compounds, the predominant compound, when platinum is employed, being CrPt 3 . The presence of the chromium also improves the etchability of the masking layer. In particular, members of the platinum family and particularly platinum cannot be etched too readily.
Both the chromium and platinum-type layers (2 and 3) are preferably applied to the substrate by sputtering techniques at elevated temperatures usually between about 100° and about 300° C and preferably about 200° C. The chromium layer 2 is preferably about 100 to about 500 angstroms thick and the platinum-type layer 3 is preferably from about 2,000 to about 5,000 angstroms thick. The coating is preferably done by sputtering techniques since such techniques ensure coating of the edges of the substrate as well. This is essential to prevent etching in undesired locations of the substrate.
Next, a second chromium layer 4 is applied. This layer 4 is preferably applied by sputtering techniques at temperatures between about 100° to 300° C and preferably about 200° C. The thickness of the chromium layer 4 is normally between about 100 and about 500 angstroms.
Next, a layer 5 of silicon dioxide is applied to the coated substrate. The silicon dioxide 5 is also preferably applied by sputtering coating techniques. The silicon dioxide layer 5 is between about 0.5 to about 2 microns and preferably about 1 to 2 microns. This layer 5 is employed as a masking layer for defining the predetermined hole in the platinum-type containing layer. Normal photoresist materials cannot be employed to define the platinum-type layer since such materials normally do not withstand the etching compositions needed to etch the platinum-type containing layer and particularly do not withstand aqua regia. Accordingly, the requirement for this particular layer 5 is that it is capable of withstanding the etching materials needed to etch the platinum-type containing layer and particularly capable of withstanding action by aqua regia and must be adherent and nonreactive with the platinum-type layer beneath it. For instance, an attempt with silicon nitride as this layer 5 was unsuccessful since such reacted with the platinum-type layer and therefore was not suitable for the purposes of the present invention.
The layer 4 of the chromium is important since it enhances the bonding between the platinum-type layer 3 and the silicon oxide layer 5.
Next, the coated structure is heated in an oxygen atmosphere and preferably in pure oxygen to form the metallic compounds of the member of the platinum family and chromium in order to improve the adhesion to the substrate. The heating is generally between about 700° and 1,100° C for between about 15 minutes to about 2 hours. The temperature and time should be sufficient to allow for complete reaction between the member of the platinum family and chromium but not excessive so as to avoid undue grain growth of the platinum-type chromium layer. Generally it is found that between about 15 minutes and about 2 hours at temperatures between about 700° and about 1,100° C are sufficient for this purpose. The silicon oxide layer helps to provide the proper rate of oxygen diffusion through the layers to contact the member of the platinum family and chromium for improving the bonding of the reacted compound masking layer to the substrate. It has been found that this heat treatment in pure oxygen with a member of the platinum family alone such as platinum without the chromium did not provide sufficient adhesion to the substrate.
Desired openings in the silicon oxide layer are now achieved by employing standard photoresist techniques. For instance, a layer 6 of a positive photoresist is applied to both sides of the substrate such as a photoresist available under the tradename AZ-1350. Next, a mask is applied on top of the photoresist so as to expose only those portions of the photoresist to ultraviolet light or electron beam radiation which is to be removed to represent the holes or openings in the silicon dioxide layer below.
After exposure to the radiation, those portions of the photoresist exposed thereto will be removed upon application of the etching material for the silicon oxide. One particular etchant employed is buffer HF at room temperature. This etches the SiO 2 in the area previously containing the exposed portions of the photoresist material but does not attack the unexposed photoresist material nor the silicon dioxide material under the photoresist and protected thereby.
Next, the entire photoresist material is removed, for instance, by dissolving in acetone. The silicon oxide layer now serves as the mask to etch corresponding holes in the platinum-type chromium layers. A preferred etchant for providing holes in the platinum-type layer is aqua regia (1HNO 3 :3HCl). The etching is normally carried out at temperatures between about 50° and 85° C, from about 1/2 to about 5 minutes. The preferred temperatures are from about 50° to about 60° C.
The silicon dioxide layers 5 are now removed with buffered HF at about room temperature. The buffered HF does not affect the platinum-type metallic layers.
The platinum-type chromium layer now acts as a mask for the substrate. The exposed areas of the substrate are then etched in a mixture of the sulfuric and phosphoric acid at temperatures between about 200° and about 325° C and preferably at temperatures between about 250° and 300° C. The most preferred temperature for sapphire is about 285° C. The acid mixture can contain from about nine parts sulfuric acid to one part phosphoric acid to one part sulfuric acid to nine parts phosphoric acid by volume.
The time required for this step in the process depends upon the specific acid composition employed, the temperature of the treatment and upon the thickness of the substrate. Normally the rate of etching of the substrate is about 12 microns per hour depending upon such factors as the depth of the hole being etched, and the size of the hole. The etch rates through the masked substrate will always be at least equal to and in most cases greater than the etch rate on unmasked blanks of the substrate. This is due to what is known as flux enhancement phenomenon since as the hole gets smaller as it converges, more etching material is available per hole area.
The shape of the openings in the mask can be varied but is preferably substantially a circular hole. Employing a circular hole tends to facilitate obtaining more readily a well defined crystallographic geometry. For instance, as shown in FIGS. 2A to 2D, starting with a circular hole for a sapphire substrate resulted in a triangular hole at the bottom of substantially straight and equal size. As used herein terms such as "substantially triangular" and "substantially square" include not only shapes wherein the sides are straight lines but also include shapes wherein the sides are arced to some degree as shown in FIGS. 2B and 2C.
FIGS. 2A-2D are magnified sequential photographs of a (0001) sapphire wafer 11 treated in accordance with the present invention. The photographs are by interference contrast. The wafer is about 10 mils thick. The diameter of the circular mask or opening is about 32 mils. FIGS. 2A-2C are photographs wherein the holes 13 have not yet been etched through the wafer. In FIG. 2D, the holes are formed through the wafer. Each side of the triangular hole 13 in FIG. 2D is about 1.5 mils.
FIGS. 3A-3C are magnified photographs by scanning electron microscope of a (0001) sapphire wafer 21 treated according to the process of the present invention. FIGS. 3A and 3B are magnified about 1,440 times.
FIG. 3A is a photograph wherein the holes 23 have not yet been etched through the entire wafer. In FIG. 3B, the holes are formed through the wafer 21. FIG. 3C corresponds to FIG. 3B except that it is of a lesser magnification thereby permitting a somewhat improved view of the original circular hole in the mask 24. In FIGS. 3A-3C, 22 represents the converging walls of the hole.
FIG. 4 represents top perspective view of a substrate 31 of (100) orientation processed in accordance with the present invention. The apertures are pyramid-like having 4 sides 32 resulting in a square hole 33 at the bottom of the substrate.
The following examples are provided to further illustrate the present invention.
EXAMPLE 1
A metallic chromium layer of about 300 angstroms is applied to one side of a (0001) sapphire substrate by sputtering at a temperature of about 200° C. Next, a layer of about 5,000 angstroms of platinum is applied to the coated side of the substrate by sputtering at a temperature of 200° C. This is followed by a second layer of chromium of about 300 angstroms on the coated side of the substrate being applied by sputtering at about 200° C. Next, a silicon oxide layer of about 5,000 angstroms is sputtered onto the coated side of the substrate at a temperature of about 200° C. The above sequence of layers is repeated on the other side of the substrate or provide the coated structure as illustrated in FIG. 1A.
The coated substrate is then heated for about 1 hour at 1050° C in pure oxygen. Next, a positive photoresist coating such as AZ-1350 is applied to all surfaces of the coated substrate. A mask having substantially circular openings is then applied after which the unmasked portions of the photoresist are exposed to ultraviolet light. Corresponding circular openings are obtained in the silicon dioxide layer by etching with buffered HF at about room temperature. The unexposed photoresist material is now removed by dissolution in acetone. The silicon oxide layer now serves as a mask to etch holes in the platinum-containing layer. The openings in the platinum layer are etched by employing aqua regia (1NHO 3 :3HCl) at about 60° C for about 3 minutes.
After opening the holes in the platinum-type layer, the exposed sapphire substrate is etched in a mixture of one part by volume sulfuric acid to one part by volume phosphoric acid at a temperature of about 285° C. FIGS. 2A-2D are photographs of the progression of the hole at it is etched in the sapphire substrate. As noted, the holes formed on the basal plane of the sapphire are three-sided, converging to a point at the bottom. It was observed that the etching rate is relatively rapid until the three converging planes meet, and then the rate becomes much slower since it is determined by the newly exposed planes. These new, slow etching planes form an angle of about 32.4° with the starting surface. By selecting the thickness of the sapphire wafer, the diameter of the hole in the platinum mask, the particular dimensions of the triangular hole can be readily determined. For instance, a 4 mil thick sapphire wafer would require about a 13 mil diameter hole to form a triangular opening of one mil on an edge.
EXAMPLE 2
Example 1 is repeated except that the substrate employed is a yttrium aluminum garnet having orientation (100). The holes achieved are four sided pyramids resulting in a square hole at the bottom as illustrated in FIG. 4. It is noted however that some undercutting of the circular mask did occur. Moremover, etching the (100) surface of magnesium aluminum spinel and the (100) surface of yttrium iron garnet would result in a geometric structure substantially the same as the structure achieved with the yttrium aluminum garnet. The adhesion between the platinum chromium layer and magnesium aluminum spinel was not quite as good as the adhesion with the sapphire surface.
The sulfuric acid utilized in the practice of the present invention is concentrated sulfuric acid which is a concentrated aqueous solution containing about 95-98 weight percent H 2 SO 4 . The phosphoric acid utilized is concentrated phosphoric acid which is concentrated aqueous solution containing 85 weight percent H 3 PO 4 .
The orientations indicated hereinabove are well known to those skilled in the art of crystallography. The nomenclature utilized [(100), (0001)] describes the sets of planes within a crystallatice which form crystal faces and these are characterized as Miller Indices. For a more detailed explanation of Miller Indices. see Van Nostrand's Scientific Encyclopedia, Third Edition, under "crystallography" on page 456. This subject is also discussed in still more detail in the "Textbook of Physical Chemistry" by S. Glasstone, Second Edition, pages 340-46, D. Van Nostrand Company, Inc. | A method for etching at least one aperture having a defined crystallographic geometry in single crystals which includes masking the crystal to protect predetermined portions thereof from being etched, and then anisotropically etching with a mixture of sulfuric acid and phosphoric acid. | 2 |
[0001] This is a continuation-in-part of provisional application Ser. No. 60/201,120 filed May 2, 2000 to which benefit of its filing date is hereby claimed under 35 U.S.C. § 120, and which is hereby incorporated by reference in its entity herein.
BACKGROUND OF THE INVENTION
[0002] Conventional burn-off ovens of the batch type are used to incinerate contaminant or undesired coatings. Typically these burn-off ovens treat hangers or part support structures for carrying parts to be coated via a wet or dry coating system which system has conveyance means such as a monorail, chain on edge, belt driven or other transfer mechanism. Also production painted parts and/or parts to be stripped for recoating after normal service are typically treated in such type burn-off ovens. The rejected parts can arise from use of hangers or support structures for the parts being treated which have gone through the coating process numerous times placing them in condition where the build up coating can begin to flake off and contaminant the production parts. It becomes necessary to monitor hanger use cycle times in order to ensure that they are thermally processed in a burn-off oven such flaking of the coating can take place.
[0003] Typical process hardware and a process method may involve continuous in line hangers or part support structures carrying work pieces through a coating spraying system for coating the work pieces, resulting in the hangers and part support structures likewise being at a minimum partially coated. This requires the hangers to be removed from the production line and to be moved in a cart to the batch type burn-off oven. The burn-off oven heats the contents of the cart to a temperature capable of incinerating the coatings on the hangers or other coated parts, over a period of 3 to 12 hours.
[0004] In some cases, some ash or residue remains on the processed parts and it may be removed physically such as by a brushing or washing process. The cleaned hanger or support part can then be placed back in service for the next process cycle. In order for the contaminant or undesirous coating to be incinerated in the burn-off ovens they must attain very high temperatures (depending on the thickness of coating materials). Therefore, extensive time is required for the thermal energy to be transferred from the energy source to the contaminated parts. Typically this energy is transferred using convection heating methods due to the number of parts being treated at one time masking them from the use of radiant, impingment or like type alternate heating methods.
FIELD OF INVENTION
[0005] This invention pertains to the art of methods and apparatuses for cleaning contaminants from articles, and more specifically to methods and apparatuses for incinerating the contaminants.
SUMMARY OF THE INVENTION
[0006] The present invention incorporates the utilization of high watt density electric infrared heaters and other high energy heating methods appropriately designed and arranged to incinerated accumulated coatings on work piece carrier hangers and/or coatings from work pieces for refinishing while they are carried through a burn-off oven which is located in-line with the normal in-line coating process line.
[0007] Typically exposure time in the burn-off oven is in the order of one minute. It is not necessary to remove the work piece support carriers or work pieces from the conveyor line to accomplish the desired stripping function in a remote high energy batch heating system.
[0008] In some cases the ash resulting from the process is so minimal that a cleaning process is not required.
[0009] The electric infrared heaters are specifically designed by utilizing high temperature emitters to create rapid heating rates and incorporate high temperature reflective refractories with critical air cooling provisions for improved heater lamp life and heater longevity. Preferably the high energy heating section is completely enclosed to shield operational personnel and to retain any affluent gases created in the burn-off process.
[0010] After the burn-off process the work piece support hangers and/or work pieces to be stripped may pass through a cleaning station for removal of ash residue. The cleaned hardware then continues through the production cycle.
[0011] The system is designed for continuous in-line operation and may be utilized during all in-line processing; however, the burn-off oven may be deactivated and programmed for specific utilization time where intermittent usage is adequate. Further, the user may choose to utilize the burn-off oven on a side track in an off-line arrangement from the in-line production arrangement; however, utilizing the advantage of not having to remove the work piece carrier supports.
[0012] Where necessary burn-off oven installations incorporate affluent gas removal hardware for transferring such gases to a gas burning incinerator which incinerator is known in the prior art.
[0013] The system includes necessary control equipment such as a switch gear, temperature controllers, logistic controllers, safety devices, limiting devices and alarming devices as necessary for system control.
[0014] In one aspect the invention is a method of rapid incineration of contaminants on articles in a continuous moving environment without removal of the articles from the conveyance means and includes the following steps. Passing the articles in situ of the conveyance means past a high intensity energy source thereby elevating the temperature of the contaminant on the article to the incineration point. Supplying energy to the high energy source in proportion to the speed of the moving articles whereby the time of the articles within the high energy source equals the time necessary to bring the contaminant to the incineration point.
[0015] The invention is also a method of rapid heating continuous moving in-line system articles using a high intensity energy source to enable the articles to be cleaned by rapid incineration of contaminants on the articles without removal of the articles from the in-line system conveyance means thereby saving time required from removal and reinstallation of articles as well as shortening heating time.
[0016] The invention also anticipates an apparatus for enclosing a continuous in-line system article high energy incineration station including;
[0017] a. a container capable of sustaining a negative pressure;
[0018] b. an exhaust system;
[0019] c. a low pressure inlet/outlet seal; and
[0020] d. an inner face to a gas incinerator burn-off.
[0021] The present invention has the advantage over the prior art batch burn-off systems of faster heating to reduce cleaning time in a production environment. More production time is saved because hangers do not have to be removed from the line. The same is true for support structures. Additional time is saved because the hangers and structures do not have to be reinstalled. A further advantage is there is no need to monitor when cleaning is required such as counting the number of coatings on the hangers. Still another advantage is fewer hangers are needed since a batch type oven may be processing hangers while the coating line is in operation. As a result the invention prevents contamination of treated parts by flaking off of contaminant from hangers over due for cleaning, and fewer hangers are needed by the system of the present invention since those in a batch type oven cannot be used in production whereas the same situation does not occur with the in-line system of the present invention.
[0022] The present invention enhances efficiency by cleaning hangers every time it is used, if desired, requiring less energy and possibly eliminating the need for physical removal of residue. Further advantages of the present invention will be apparent upon review of the following detailed description.
BRIEF DESCRIPTION OF THE DRAWING
[0023] The invention may take physical form in certain parts and arrangement of parts, a preferred embodiment of which will be described in detail in this specification and illustrated in the accompanying drawings which form a part hereof and wherein:
[0024] [0024]FIG. 1 is a schematic view of an in-line production facility incorporating an in-line burn-off oven of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0025] Referring to the drawing of FIG. 1, a typical in-line system for treating articles incorporating an embodiment of the present invention is illustrated. A monorail 28 provides conveyor support structure for the conveyance means through the in-line system but the conveyance means could be other than the monorail illustrated such as a belt drive, chain drive, etc.
[0026] A monorail 28 supports hangers 13 which in turn support articles to be treated in the in-line system. Starting to the left, article 22 moves from left to right, thereby first entering a coating spraying station 23 where articles, both the hanger 13 and work piece 22 , are sprayed to provide that the work piece 22 is completely coated with an appropriate coating. Oven spray is conveyed by exhaust 24 to a coating collection point or for appropriate disposal and work pieces 22 emerge from the coating station having been completely coated as uncured coating work pieces 27 .
[0027] Those pieces 27 then move into the drying or curing station 25 , depending on the coating which may be a wet paint or a dry powder coating such as a polymer. Any affluent from the station 25 is transferred by the exhaust 26 to a conventional gas burning incinerator, not illustrated.
[0028] Upon leaving the curing station 25 the work pieces 27 which entered therein now have a coating 14 thereon which is thereby finished by being dried or completely cured. At this point the work piece 27 being completed can be removed from the production line and the hanger 13 may now continue on into the in-line heating station 15 which has a heating unit 16 of a high intensity energy source for quickly bringing the coating on the hangers 13 to the coating incineration point. This incineration point will vary with varying coatings but is, in each case, that temperature required to incinerate the coating to ash. A hanger 13 now having been cleaned is ready for use at position 21 .
[0029] Where necessary a physical cleaning station 20 may be provided to physically remove any ash or like type contaminant which may remain using such things as brushes or a fluid spray.
[0030] Alternatively if the finished work piece 14 is found to be unsatisfactory rather than being removed at the exit of the curing station 25 the finished work piece 14 itself may continue on with the hanger 13 to the in-line heating stations 15 to also be cleaned in the same manner as the hanger 13 . Upon its exit from the inline heating station 15 the cleaned work piece 22 can be removed from the line for recoating.
[0031] It is envisioned also that the in-line heating station could be located off-line from the monorail 28 which supports the production line. Still, in this case the inline heating station 15 would remain a high intensity energy source with a continuous flow of operation.
[0032] It should be noted that the coating station 23 , to assure complete coverage of the work pieces 22 , will provide a spray sufficient to coat at least a portion of the hangers 13 so that coating occurs complete from the coating mark 12 on the hangers 13 to the bottom of the coated work piece 27 . Clearly, this coating mark carries over into the curing station and results in the coating being cured on the hangers 13 as well. It can be appreciated that there are systems where the hangers carry part support structures wherein the work pieces are sophisticated and require the support of such structures e.g. auto parts. These part support structures also end up below the coating mark 12 . Thus, the hangers 13 , part support structures, and the work piece 22 all can at one time or another be articles which pass through the heating station 15 for the purposes of cleaning.
[0033] The in-line heating station 15 incorporates a control unit 19 for the high energy source including conventional equipment such as switch gear, temperature controllers, logistic controls and limiting and alarming devices necessary for system control and proper operation. An enclosure 30 includes an inlet seal 17 as well as an exit seal, not illustrated, together with an exhaust system 32 having an affluent exhaust 18 creating an inner face between the exhaust system and a gas burning incinerator, not illustrated.
[0034] In a preferred embodiment of the present invention, coated hangers 13 are passed through the in-line heating station 15 each time that they are coated by the in-line system together with the production line work pieces 22 . The hangers 13 are uninterrupted moving on a continuous basis past the high intensity energy source of a heating unit 16 operating in a range of 100 to 500 watts per square inch and preferably at 200 watts per square inch using short wave length energy of 1.0 to 5.0 microns and preferably 1.0 to 3.0 microns to elevate the coating contaminant on the hangers 13 to a temperature range of 800 to 2000° F. preferably 1000° F. within a time range of thirty to ninety seconds preferably one minute.
[0035] To obtain the above short heating times and high temperatures the heating station 30 and the high intensity energy source heating unit 16 was provided with high watt density electric infrared heaters. Other high intensity energy sources such as induction heating, electron beam, microwaves or open flame impingment, to name a few, could be used but they each present their own limitations. For example, induction heating requires a metallic article, while microwaves cannot tolerate metallic parts. The preferred infrared heaters do not have this limitation. Even more preferably, the heating unit 16 is provided with high temperature emitters incorporating high temperature reflective refractories, tungsten elements operating at temperatures ranging to 5000° F. and critical air cooling provisions. The use of short wave length energy allows penetration of the coating to thereby heat the article to incineration point temperatures as well as the coating contaminant. In this embodiment the coating was a wet application of paint.
[0036] It is also anticipated by the present invention that where the hangers 13 are narrow, and spaced far apart, the high intensity energy source would need to be arranged vertically to the direction of flow of the articles passing through it to provide a narrow heating zone which can be energized only when the article is within the field of heating of the high intensity energy source. This enhances the efficiency of the heating station 15 . Such efficiency is possible and particularly enhanced by the ability of the preferred infrared heating unit's rapid heating rate which can be taken from zero to full energy within one to two seconds.
[0037] In another preferred embodiment of the present invention, using the same heating unit 16 identified in the above embodiment, a tubular work piece coated with cured powder paint and of a rectangular cross section with a wall thickness of about {fraction (3/16)}″ and ⅛″ was passed by the heating unit 16 in 25 to 30 seconds to incinerate the paint on the ⅛″ thick portion, while to obtain the same results for the {fraction (3/16)}″ section required 50 to 60 seconds. Water was then sprayed on the tubular work piece which was still at or near incineration point temperature of the coating. Upon inspection the following day only a light powder residue, which wiped off with a finger touch, remained.
[0038] Lastly, in a third embodiment of the present invention the work piece 22 to be treated was an angle iron of rectangular cross section varying in thickness from ⅛″ to ¼″; the thicker portion being in the corner of the angle which required 40 seconds to bring the work piece in the thickest section to 1245° F. resulting in the coating thereon turning to ash.
[0039] From the above embodiments it can be appreciated that the material and physical make-up of the work piece, in addition to the coating of the work piece, such as the number of layers, significantly impact the method of the present invention, but in all instances the high intensity, short wave length energy source which penetrates the coating to be incinerated is the key to the short heating times permitting continuous and even in-line treating of work pieces to clean them or other articles of contaminants such as coatings.
[0040] It is anticipated that there is no limit to the variety of coatings which could be treated. Teflon coatings for example are anticipated to require temperatures as high as 1500° F. while the system is capable of temperatures ranging 2000° F. to 2500° F. on the hanger or work piece.
[0041] The invention has been described with reference to preferred embodiment. Obviously, modifications and alterations will occur to others upon a reading and understanding of this specification. It is intended to include all such modifications and alternations in so far as they come within the scope of the appended claims or the equivalence thereof.
[0042] Having thus described the invention, it is now claimed: | Method and Apparatus for high intensity infrared burn-off of contaminants on articles moving continuously through an in-line production process. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This patent application is a division of U.S. patent application Ser. No. 11/446,283, filed on Jun. 2, 2006, now U.S. Pat. No. 7,461,767, which claims priority to U.S. Provisional Patent Application Ser. No. 60/687,406 to Viola, et al., filed Jun. 3, 2005 and to U.S. Provisional Patent Application Ser. No. 60/687,244 to Viola, et al., filed on Jun. 3, 2005, which are herein incorporated by reference in their entirety. This application also relates to U.S. patent application Ser. No. 11/446,282 to Viola, et al., filed Jun. 2, 2006, now U.S. Pat. No. 7,464,847, which is herein incorporated by reference in its entirety.
BACKGROUND
1. Technical Field
The present disclosure relates to surgical instruments. More particularly, the present disclosure relates to a surgical stapling device that has an improved and internally powered driving mechanism.
2. Background of the Related Art
Surgeons have recognized in the art the benefits of a compact surgical apparatus for the application of surgical dips and staples to body tissue in a number of different medical procedures. Often, prior art surgical staplers require some degree of physical force or lateral movement in order to operate a handle to actuate the surgical stapler and fire the staple after a compression to actuate the surgical stapler and fire the staple after a compression of tissue is made. It would be desirable to have a precise surgical stapler device that is compact and easy to use and will quickly and easily fire. Also, once compression of the desired stapling location is made, only a very limited degree of force to the surgical stapling device should be required in order to complete the actuation of the device and thus firing of the staples such as by actuating a trigger switch. Moreover, such a powered stapling device should be very easy to manipulate and hold by the surgeon.
Attempts have been made in the art to provide such a surgical stapling device that is pneumatic or gas powered and/or also externally powered in order to remedy this desire. However, it would be beneficial to provide a disposable apparatus for the application of staples to body tissue that is self contained, self powered and easy to manufacture.
SUMMARY
According to a first aspect of the present disclosure, there is provided a surgical stapler. The stapler has a handle assembly including a stationary handle and a trigger. The trigger is configured to manipulate a cam member through an actuating stroke. The stapler has an elongated body extending distally from the handle assembly and defining a longitudinal axis with a staple cartridge supported adjacent the distal end of the elongated body and containing a plurality of staples. The stapler has an anvil pivotally mounted in relation to the cartridge adjacent the distal end of the elongated body. The anvil has a fastener forming surface thereon and is mounted for pivotal movement in relation to the cartridge between an open position having a distal end spaced from the staple cartridge and a closed position in close cooperative alignment with the staple cartridge. The stapler has an actuation sled supported within the cartridge. The actuation sled is movable to urge the plurality of staples from the cartridge. The stapler also has a drive assembly with a body having a working end and a cam member supported on the working end. The cam member is positioned to translate relative to the anvil to maintain the anvil in the closed position during firing of the stapler.
The trigger is operatively connected to a power cell. The power cell is operably connected to a motor of the drive assembly. The manipulation of the trigger actuates the power cell such that the power cell powers the drive assembly to effect translation of the cam member relative to the anvil. The stapler also has a channel for supporting the staple cartridge and the motor of the drive assembly controls the actuation sled supported within the cartridge. The actuation sled urges the plurality of staples from the cartridge when the anvil is in the closed position and in cooperative alignment with the staple cartridge.
According to another aspect of the present disclosure, there is provided a surgical stapler. The stapler has a handle assembly with a stationary handle and a trigger configured to manipulate a cam member through an actuating stroke. The stapler also has an elongated body extending distally from the handle assembly and defining a longitudinal axis. The stapler also has a staple cartridge supported adjacent the distal end of the elongated body and containing a plurality of staples with an anvil pivotally mounted in relation to the cartridge adjacent the distal end of the elongated body. The anvil has a fastener forming surface thereon and is mounted for pivotal movement in relation to the cartridge between an open position having a distal end spaced from the staple cartridge and a closed position in close cooperative alignment with the staple cartridge.
The stapler has an actuation sled supported within the cartridge. The actuation sled moves to urge the plurality of staples from the cartridge. The actuation sled is connected to a drive rack. The drive assembly has a body with a working end and a cam member supported on the working end. The cam member is positioned to translate relative to the anvil to maintain the anvil in the is closed position during firing of the stapler.
The trigger is operatively connected to a power cell. The power cell is operably connected to a motor of the drive assembly such that manipulation of the trigger actuates the power cell such that the power cell powers the drive assembly to effect translation of the cam member relative to the anvil. The stapler also has a channel for supporting the staple cartridge. The motor of the drive assembly controls the actuation sled supported within the cartridge. The actuation sled urges the plurality of staples from the cartridge when the anvil is in the closed position and in cooperative alignment with the staple cartridge.
The stapler also has a protective casing. The protecting casing houses the power cell and the motor in the protective casing and is connected to the stationary handle. The motor has a motor drive shaft that extends through the stationary handle to connect with the drive rack.
According to another aspect of the present disclosure, the surgical stapler is powered by an inexpensive disposable power source that may be actuated by a manual or automatic switch or switch system and that has a power cell coupled to a motor assembly to assist with actuation and firing of the staples.
In another embodiment, the stapler has a power supply that can actuate is the stapler and the power source can easily move the drive mechanism to an appropriate position for the next stapling operation.
According to another aspect of the present disclosure, there is provided a surgical stapler. The stapler has a handle assembly including a trigger and a clamping device including a staple cartridge with a plurality of staples and an anvil having a fastener forming surface thereon. The stapler also has a controller configured to determine an occurrence of clamping by the anvil and the staple cartridge. The controller controls firing of the plurality of staples from the staple cartridge. When the trigger is actuated the controller delays firing of the plurality of staples from the staple cartridge to provide for a predetermined time period of tissue compression of the tissue between the anvil and staple cartridge. The controller outputs a control signal to allow firing once the predetermined time period is reached. The stapler also has a motor having a geared assembly. The motor is disposed in the handle and configured to receive the control signal from the controller. The motor is operatively connected to the staple cartridge to fire the staples from the staple cartridge once the control signal is received.
DESCRIPTION OF THE DRAWINGS
Other and further objects, advantages and features of the present disclosure will be understood by reference to the following specification in conjunction with the accompanying drawings, in which like reference characters denote like elements of structure and:
FIG. 1 is a perspective view of a first embodiment of a surgical stapler of the present disclosure;
FIG. 1A is a schematic of the handle portion of the surgical stapler of FIG. 1 showing the trigger switch and a power cell coupled to a motor;
FIG. 2 is an exterior cross sectional view of the surgical stapler along line 2 - 2 of FIG. 1 with the surgical stapler having a drive compartment thereon;
FIG. 3 is an interior cross sectional view of the surgical stapler being opposite the compartment;
FIG. 3A is an exploded view of a channel of the surgical stapler of one embodiment of the stapler;
FIG. 3B is an exploded view of the staple cartridge, anvil and the drive sled of FIG. 1 ;
FIG. 4 is another cross sectional view of another embodiment of the surgical stapler of FIG. 1 having a drive source in the handle of the surgical stapler;
FIG. 4A illustrates another cross sectional view of the surgical stapler of FIG. 1 having a bevel geared arrangement;
FIG. 5 is a cross sectional view of an endoscopic portion of the surgical stapler of FIG. 4 ; and
FIG. 6 is yet another cross sectional view of another embodiment of the surgical stapler of FIG. 1 with the drive source being in the handle and geared to the drive screw of the surgical stapler.
DETAILED DESCRIPTION
In the drawings and in the description which follows, the term “proximal”, as is traditional, will refer to the end of the apparatus which is closest to the operator, while the term “distal” will refer to the end of the apparatus which is furthest from the operator.
The present disclosure shall be discussed in terms of both conventional and endoscopic procedures and apparatus. However, use herein of terms such as “endoscopic”, “endoscopically”, and “endoscopic portion”, among others, should not be construed to limit the present disclosure to an apparatus for use only in conjunction with an endoscopic tube. To the contrary, it is believed that the apparatus of present disclosure may find use in procedures in these and other uses including but not limited to where access is limited to a small incision such as arthroscopic and/or laparoscopic procedures, or any other conventional medical procedures known in the art.
Referring now to the figures, wherein like reference numerals identify similar structural elements of the subject disclosure, there is illustrated in FIG. 1 a self-contained powered surgical stapler constructed in accordance with one embodiment of the subject disclosure and designated generally by reference numeral 10 . The surgical stapler 10 is a disposable surgical instrument. However, the disposable arrangement is non-limiting and other non-disposable arrangements may be contemplated and are within the scope of the present disclosure.
The surgical stapler 10 of the present disclosure shown in a perspective view in FIG. 1 and described herein includes a frame generally represented by reference numeral 12 and handle generally represented by reference numeral 14 . The frame 12 defines a series of internal chambers or spaces for supporting various mechanical components of the surgical stapler 10 as well as a number of staples therein for the application to the body tissue.
The frame 12 supports an endoscopic portion 16 or an extended tube-like portion. The endoscopic portion 16 is capable of being rotated and has a relatively narrow diameter, on the order of in a range that includes about 10 millimeters, and is for insertion into a small opening in or tube inserted into the body, such as in the abdominal cavity, or other similar body cavities. The endoscopic portion 16 has a longitudinal axis and has a length. The length is appropriate for reaching the operation site in the interior of the body. The surgical stapler 10 may be used in conjunction with other instruments such as endoscopes or other such optical devices for visually examining the interior of the body, for example, cameras by means of fiber optics or other optical or recording devices.
Generally, the endoscopic portion 16 of the surgical stapler 10 is inserted through the small opening or wound, and is manipulated to the operation site. At the operation site, the surgical stapler 10 is actuated.
The endoscopic portion 16 has a fastening assembly 18 and cutting assembly that is known in the art. The fastening assembly 18 and the cutting assembly are located in a housing 20 which carries a fastener and a cutter to the operation site. The fastening assembly 18 in this one non-limiting embodiment has a pair of jaws 21 , 22 , or an anvil 22 and a staple cartridge 21 . The jaws 21 , 22 may be a first jaw 21 and second jaw 22 that opens and closes or alternatively another clamping structure for compression of the tissue at the stapling site. The jaws 21 , 22 are defined by a staple carrying cartridge 21 and the anvil 22 that is located therein. The staple carrying cartridge 21 is in one embodiment located at the distal end of the housing 20 . The staple carrying cartridge 21 has one or a number of rows of staples. The surgical stapler 10 also has an anvil 22 with a forming surface (not shown) and further includes a knife (not shown) as is well known in the art for accomplishing the surgical stapling.
Generally, actuating the operating portion of the fastening assembly 18 is accomplished via intermediate components disposed on or within the narrow longitudinally extending tubular endoscopic portion 16 . In one embodiment, a cylindrical tubular sleeve member surrounds the endoscopic portion 16 . The sleeve may be manipulated in a direction with the longitudinal axis of the surgical stapling device. The surgical stapler 10 of the present disclosure has three basic actions or functions.
First, the endoscopic portion 16 is introduced into the human or animal body and is positioned with the jaws 21 , 22 aligned at the desired stapling site to receive the target tissue. This may involve rotation of the endoscopic portion 16 relative to the body, either by rotating the surgical stapler 10 , as a whole, by rotating simply the endoscopic portion 16 relative to the frame 12 as permitted, or a combination of both actions. Thereafter, the surgical stapler 10 secures the target body tissue between the staple cartridge 21 in the distal portion of the housing 20 and the anvil 22 . This is accomplished by a clamping action of the jaws 21 , 22 or alternatively by another similar or different clamping member. The jaws 21 , 22 are allowed to remain in the closed position for a period of time. The jaws 21 , 22 remaining closed for a predetermined period of time allow any is excess liquid or fluid in the tissues to drain out of the body tissues prior to actuation of the stapling mechanism. This ensures that the liquid does not rapidly traverse out of the tissues to impede formation of the closed or formed staple and ensures a proper staple formation.
With the target tissue clamped between the anvil 22 and the staple cartridge 21 , a camming surface which surrounds the housing 20 and anvil member 22 may be employed to close the jaws 21 , 22 of the surgical stapler 10 and clamp the tissue between the anvil 22 and the tissue contacting surface of the staple cartridge 21 . The jaws 21 , 22 may be clamped by actuating or closing lever 24 that is opposite the jaws 21 , 22 . Thereafter, the third action of the operator or more particularly the surgeon is that of applying the staples to the body tissue. A longitudinally extending channel is employed to deliver longitudinal motion to an axial drive member and a tissue cutting knife.
The stapler 10 may have an axial drive member or an axial drive screw to contact a pusher. The pusher elements drive the staples through the body tissue against the fastener or forming surface of the anvil 22 . Typically, in the art the surgical stapler 10 fires usually by an actuation of a first trigger 26 . Thereafter, the clamping action of the jaws 21 , 22 is released and the surgical stapler 10 or a portion thereof may be withdrawn from the body cavity or site.
A known and recognized benefit is that often an operator will desire a surgical stapler 10 that is self-actuating or that actuates with only a limited degree of physical force using the trigger handle (not shown) or using a trigger switch 26 . It is envisioned that surgeons would desire such a surgical stapler 10 that does not have to be connected to any external power supply but instead includes an internal battery operated power supply. Operators would desire a surgical stapler having an internal power source that is comfortable to hold, compact and that is very suitable for endoscopic or laparoscopic procedures as well as other conventional surgical procedures. The stapler 10 of the present disclosure is advantageous since it is a compact and ergonomic member. It is also very advantageous to form such a surgical stapler 10 from few component parts relative to the prior art surgical instruments. This reduces manufacturing costs of the surgical stapler.
The present disclosure in one embodiment uses a motor drive source having a substantially offset or a direct drive to remedy these known issues in the art. FIG. 1A shows a schematic illustration of an interior of the handle 14 . The surgical stapler 10 in this embodiment is powered by a motor 30 . The trigger switch 26 in this embodiment is connected by lead 27 to a power source 29 such as a battery. The battery 29 is connected by lead 31 to a motor 30 . The motor 30 is connected by lead 31 to the switch 26 . Upon the actuation of switch 26 , power will traverse from the battery 29 to the motor 30 . The energized motor 30 will rotate the motor drive shaft 32 to spin gear 68 . Gear 68 is in contact with gear 70 . Gear 68 rotates second gear 70 which will rotate drive screw 66 . The drive screw 66 upon rotation will move in a longitudinal manner to actuate one or more other components of the surgical stapler 10 such for compression of tissue or stapling. Although, the battery 29 and the motor 30 are shown as being located in the handle 14 , other locations are contemplated.
Referring now to FIG. 2 , there is shown a cross sectional view of the surgical stapler 10 of the present disclosure along line 2 - 2 of FIG. 1 from a rear view of the surgical stapler of FIG. 1 . Disposed on an adjacent side of the surgical stapler 10 is shown a protective housing 28 . The protective housing 28 is for housing one or more components of the surgical stapler 10 . The protective housing 28 may be disposed on either adjacent side of the handle 14 or in another position being parallel with the handle. The protective housing 28 is a generally a cylindrical compact member having an interior that is disposed adjacent to, and on a lateral side of the handle 14 . The protective housing 28 is made from a suitable thermoplastic member that is suitable for surgical procedures and has a suitable volume to hold one or more commercially available batteries, or another power source. Although shown as cylindrical, other shapes are possible and the protective housing 28 is not limited to this configuration. The protective housing 28 has the interior space. The space has a compact size and has an advantageous drive source 30 disposed therein.
The surgical stapler 10 of the present disclosure may have a first axial drive shaft for operation of the stapling mechanism in the proximal end of the surgical stapler 10 as is known in the art. Such stapling mechanisms are well known in the art and may be found in U.S. Pat. No. 6,330,965 B1 to Milliman, et al., 6,250,532 B1 to Green, et al., 6,241,139 B1 to Milliman, et al., 6,109,500 to Alli et al., 6,202,914 B1 to Geiste, et al., 6,032,849 to Mastri, et al. and 5,954,259 to Viola, et al., which are all herein incorporated by reference in their entirety.
The drive source 30 has electrical contacts to an integrated power supply and an optional switch system. The drive source 30 is run by any integrated power supply that is compact, and low cost to manufacture. In one embodiment, the drive source 30 also has a suitable amount of torque in order to fire and apply the staple to the body tissue or bone, and form the staple using a forming surface disposed on an anvil. In one embodiment, the drive source 30 is a simple motor assembly having a drive shaft 32 . The motor may be any device that converts the current from the portable power cells into mechanical energy but may be any motor that is low cost and that may be disposable and easily discarded after use. The drive shaft 32 is connected through the handle 14 through a sealed aperture in the handle 14 . Aperture may be sealed using an “O” ring or similar structure to ensure no fluids enter the stapler 10 .
Alternatively, the drive source 30 may comprise any electrically powered motor known in the art. The present disclosure provides that the drive source 30 may have a number of modular components that are disposable, permanent, replaceable or interchangeable. In one aspect, the motor 30 may be a modular component and replaceable. In another aspect, the battery can be a modular component and replaceable separate from the drive source 30 . In still another aspect, both the battery and the motor of the drive source 30 may be modular components. The motor and battery may be stored in a casing or be separate units.
In one embodiment, the drive source 30 has electrical contacts to, and is powered by, one more internal power cells. The power cells may be one or more disposable or rechargeable power cells. For example, the power cells may be a nickel cadmium type battery, an alkaline battery, a lithium battery, or a nickel metal hydride and may be replaceable or disposable with the entire surgical stapler 10 . Alternatively, the power cells of the drive source 30 may also disengage from the surgical stapler 10 for recharging. Once disconnected, the surgical stapler 10 itself then may be discarded after use.
In one embodiment, the one or more power cells of the drive source 30 are disposed and oriented in a generally perpendicular fashion relative to an outer surface of the handle 14 as shown in the housing 28 and optionally may be located in a casing with the motor assembly. In this non-limiting embodiment, the surgical stapler 10 may have a discrete analog switch assembly to actuate the drive source. The switch assembly may be located in any location or on an external surface of the surgical stapler 10 , or be integral with the trigger switch is 26 . Alternatively, the drive source 30 may be actuated by a counter clockwise rotation of the protective housing 28 to actuate the drive source. Still further in another embodiment, the drive source 30 may be actuated by the trigger 26 or by simply the lowering an elevation of the lever 24 .
Referring now to FIG. 3 , there is shown an opposite lateral side cross-sectional view of the surgical stapler 10 of FIG. 2 , having the lever 24 in an elevated position or elevated and away from the handle 14 . The drive shaft 32 of the drive source 30 extends through the lateral side wall of the handle 14 and engages a gear assembly 34 . The gear assembly 34 may have any number of gears to transmit motion from the drive source 30 in protective housing 28 to another member to move a suitable driving member for stapling. The driving member is a gear rack or drive screw or other member to fire the staples in the staple cartridge 21 . Various driving configuration are possible and the present stapler 10 is not limited to any such particular driving arrangement. In this one non-limiting embodiment, the gear assembly 34 has a main gear 36 and two subordinate gears 38 , 40 . The gear assembly 34 laterally extends into the interior space of the handle 14 as shown. In one embodiment, the gear 36 is a spur gear. In one embodiment, the subordinate gears 38 , 40 are a pair of pinion gears. In yet another embodiment, instead of a pair of pinion gears 38 , 40 , the stapler 10 may have one pinion gear. Various gearing configurations are possible and within the scope of the present disclosure.
The lever 24 as shown has a first lever side 42 that has a transverse aperture 44 being disposed therethrough. The lever 24 is connected to a member 46 by a link pin 48 through aperture 44 in the lever 24 . The member 46 moves laterally through the endoscopic portion 16 . The member 46 controls the jaws 21 , 22 shown in FIG. 1 to open or close and for the surgeon to clamp the jaws of the surgical stapler 10 on or at the desired tissue site. The lever 24 also has an intermediate portion 50 . The intermediate portion 50 has a second aperture 52 being disposed in a bottom side of the lever 24 . The lever 24 is further connected to a second linkage assembly 54 through the second aperture 52 by a second link pin 56 . It should be appreciated that the powered arrangement is not limited to any such device that requires tissue approximation such as a TA surgical stapler such as U.S. Pat. No. 6,817,508 to Racenet, et al. which is herein incorporated by reference in its entirety, and the powered arrangement may encompass other staplers that do not require any such tissue approximation prior to firing.
In one embodiment, the second linkage assembly 54 has two discrete links. Each of the links is spaced apart and is connected to one another to form an integral second linkage assembly 54 . The second linkage assembly 54 is for translating a downward force from the lever 24 into an axial lateral force and for moving one or more structures in the handle 14 . The second linkage assembly 54 is further fixedly connected to an interior pin 58 of the handle 14 . The lever 24 still further has an orthogonal notch 60 . The notch 60 is disposed on the lever 24 with the notch being between the transverse aperture 44 and the second aperture 52 . The notch 60 provides clearance and prevents the lever 24 from interfering or otherwise contacting the gear assembly 34 during a firing sequence or otherwise when the drive source 30 is actuated.
As shown in the raised position, the free end 62 of the lever 24 rests elevated above the handle 14 as shown. As mentioned, when a stapling site is determined by the operator, the operator will use the jaws 21 , 22 to compress the tissue at the stapling site to clamp the tissue for a period of time. The surgeon can control the jaws by lowering or closing lever 24 (from the elevated position to a position that rests on the handle 14 ). Upon lowering the lever 24 from the elevated position above the handle 14 , the lever 24 lowers the second linkage assembly 54 .
The second linkage assembly 54 forces the lever 24 at the first side 42 to move the member 46 . The member 46 is then manipulated in a lateral axial direction opposite the handle 14 . Thus, member 46 drives the jaws 21 , 22 at the distal side of the surgical stapler 10 for clamping the selected body tissue between the jaws. In one embodiment, the member 46 may further contact a lead, switch or mechanical member in order to provide an audible or visual alert so as to inform the physician/operator that a preset period of time has elapsed for compression of tissue between the laws and the firing can begin. Various clamp arrangements are possible and the present arrangement is for illustration purposes as it is envisioned that the clamp may be powered by the drive source 30 , or by a separate drive source.
In another embodiment of the surgical stapler 10 , the surgical stapler 10 may be manually actuated for stapling. In the manual embodiment, when the desired stapling is desired, the operator will actuate either a trigger handle (not shown) or in another embodiment will actuate a handle assembly having a linkage. Still in another embodiment, the lever 24 may operate the switch assembly at an end of the lever 24 . The switch assembly 26 may be on any location of the surgical stapler 10 or may be adjacent to the protective housing 28 .
The surgical stapler 10 further has a firing member 64 . The firing member 64 is laterally disposed in the handle 14 and can optionally assist with driving an axial drive screw or another driving member to actuate the stapling mechanism in the distal side of the surgical stapler 10 . The firing member 64 may include a single driving member that can control both the clamping and the firing of the surgical stapler 10 . In another embodiment, the firing member 64 can alternatively include separate driving members with one driving member for the firing of the stapler cartridge 21 and another driving member for closing the jaws 21 , 22 . Various configurations are possible and within the scope of the present disclosure. The firing member 64 is a longitudinal member having a bottom driving surface 65 . However, the longitudinal firing member 64 can be a single component or constructed of other multiple members. The firing member 64 is disposed in a longitudinal manner in the interior of the handle 14 of the surgical stapler 10 . Upon actuation, the motor in the housing 28 spins the main gear 36 that contacts or is connected to the bottom driving surface 65 of the firing member 64 . Gear 36 rotates in a counterclockwise fashion. Thus, in this manner, the drive source 30 will rotate the gear assembly 34 that will move the firing member 64 in an axial direction toward the distal direction of the surgical device 10 and away from the handle 14 . A rotation of the main gear 36 applies a force to the firing member 64 on the bottom driving surface 65 for the purpose of axially moving the firing member in a longitudinal distal manner. This axial movement of the firing member 64 will impart an axial force the corresponding member in the endoscopic potion 16 that will engage the stapling mechanism.
A beneficial aspect of the present disclosure is that the drive source 30 will then allow a greater amount of torque to be applied to the driving member 64 relative to a manually actuated apparatus without any motor assembly 30 . A significant aspect of the present disclosure is that the drive source or motor 30 is a low cost device that may be discarded. Given that the drive source 30 may be discarded, the drive source or motor 30 may be connected to an optional analog or digital circuit on a controller to drive the firing member 64 with a predetermined amount of torque so that a considerable amount of power is released from the drive source 30 each instance the firing is desired. Moreover, the surgical stapler 10 provides that the firing member 64 is directly driven by the drive source 30 , or geared by a number of gears for the purpose of actuating the stapling mechanism without undue force or movement applied to the handle 14 or another trigger handle (not shown) of the surgical stapler 10 . This is advantageous since the surgeon can precisely locate the stapler 10 at a site and then fire the stapler 10
FIG. 3A shows an exploded view of a number of components of the surgical stapler 10 of FIG. 1 . The stapler 10 has a rack 64 that is slidable in the handle portion 14 . The rack 64 interfaces with a clamp tube 102 . On a distal side of the clamp tube 102 is a channel 104 . The channel 104 engages with the clamp tube 102 and a pair of forks 106 , 108 on a distal side thereof. The stapler 10 also has an upper cover 110 and a lower cover 112 , and an extension tube 114 . The extension tube 114 engages with a collar tube 116 . The stapler 10 also has a rotation knob 118 with a channel portion 120 . The channel portion 120 has a pair of camming surfaces 122 on a distal end. The distal end also has a crimp 124 in a distal side to receive the anvil 22 .
In operation, the rack 64 slides and moves the clamp tube 102 distally. The clamp tube 102 is provided to interconnect the handle portion 14 and the extension tube 114 . The channel 104 is slidably mounted for reciprocal longitudinal motion. The extension tube 114 provides support for the surgical stapler 10 and has slots that interface with the collar tube 116 . The surgical stapler 10 also has a support 120 for longitudinal motion and to operate the stapling mechanism as described in FIG. 2 b . The operation of these components is well known and is disclosed in U.S. Pat. No. 5,318,221 to Green, et al., which is herein incorporated by reference in its entirety.
Advantageously, the rack 64 is driven distally to advance the channel 104 in a distal manner. The channel 104 delivers longitudinal motion to a pusher cam bar or an axial drive member as is known in the art for operation of the staple cartridge 21 shown in FIG. 2 b . It should be appreciated that the components shown in FIG. 3A only illustrate one embodiment of the present surgical stapler 10 , and instead of the rack 64 , the surgical stapler 10 may have a drive screw ( FIG. 4 ) for longitudinal motion and in order to actuate the staple cartridge 21 . Referring now to FIG. 3B , there is shown an exploded view of the anvil 22 and the staple cartridge 132 having an actuation sled 169 .
Referring to FIG. 2 b , the staple cartridge 21 includes an anvil assembly 130 and a cartridge assembly 132 shown in an exploded view for illustration purposes. The anvil assembly 130 includes anvil portion 22 having a plurality of staple deforming concavities (not shown) and a cover plate 136 secured to a top surface of anvil portion 134 to define a cavity (not shown). The cover plate 136 prevents pinching of tissue during clamping and firing of the surgical stapler 10 . The cavity is dimensioned to receive a distal end of an axial drive assembly 138 .
The anvil 130 has a longitudinal slot 140 that extends through anvil portion 130 to facilitate passage of retention flange 142 of the axial drive assembly 138 into the anvil slot 140 . A camming surface 144 formed on anvil portion 22 is positioned to engage axial drive assembly 138 to facilitate clamping of tissue. A pair of pivot members 146 formed on anvil portion 130 is positioned within slots 146 ′ formed in carrier 148 to guide the anvil portion 130 between the open and clamped positions.
The stapler 10 has a pair of stabilizing members 152 engage a respective shoulder formed on carrier 148 to prevent anvil portion 130 from sliding axially relative to staple cartridge 132 as camming surface of the anvil 130 is deformed. Cartridge assembly 132 includes the carrier 148 which defines an elongated support channel 154 . Elongated support channel 154 is dimensioned and configured to receive the staple cartridge 132 which is shown above the carrier 148 in the exploded view of FIG. 2 b . Corresponding tabs and slots formed along staple cartridge 132 and elongated support channel 148 ′ function to retain staple cartridge 132 within support channel 154 of carrier 148 . A pair of support struts formed on the staple cartridge 132 are positioned to rest on side walls of carrier 148 to further stabilize staple cartridge 132 within support channel 154 , however other arrangements to support the cartridge 132 on the channel 154 can be used and this arrangement is not limiting.
Staple cartridge 132 includes retention slots 156 for receiving a plurality of fasteners 158 and pushers 160 . Longitudinal slots 156 extend through staple cartridge 132 to accommodate upstanding cam wedges 162 of the actuation sled 164 . A central longitudinal slot 166 extends along the length of staple cartridge 132 to facilitate passage of a knife blade (not shown). During operation of surgical stapler 10 , actuation sled 164 is drive distally to translate through longitudinal slot 156 of staple cartridge 132 and to advance cam wedges 162 distally and into sequential contact with pushers 160 , to cause pushers 160 to translate vertically within slots 156 and urge fasteners 158 from slots 156 into the staple deforming cavities of anvil assembly 130 to effect the stapling of tissue.
Referring now to FIG. 4 , there is shown another embodiment of the present disclosure. In this embodiment, the drive source 30 is disposed in an interior space of the handle 14 in a location to balance an overall weight of the surgical stapler 10 for a more ergonomic, comfortable design. The surgical stapler 10 , in this embodiment, has a drive screw 66 as a drive member in contrast to the rack 64 of FIG. 3A . The drive screw 66 is a threaded rod having a number of helical grooves that are intended to rotate and contact another axial member shown above to actuate the stapling mechanism in the distal location of the surgical stapler 10 once a tissue compression is made by the surgeon. Various configurations are possible, and it should be appreciated that the stapler 10 of the present disclosure is not intended to be limited to any specific stapler mechanism.
In one embodiment, the drive source 30 is disposed and lies in a longitudinal plane in the handle 14 . The drive source 30 is disposed substantially parallel to a longitudinal axis of the surgical stapler 10 . This location of the drive source 30 provides for a compact and self powered surgical stapler 10 that may be comfortably balanced and ergonomically grasped by the surgeon. The drive source 30 has the drive shaft 32 . Drive shaft 32 is connected to a first drive gear 68 . The first drive gear 68 has teeth that mesh with, and rotate a number of teeth of a second translating gear 70 as shown.
The second translating gear 70 further has a bore or aperture in a center of the second translating gear 70 . The second translating gear 70 further is connected to a collar 72 in a center of the second translating gear. The collar 72 engages the drive screw 66 of the surgical stapler 10 . A clockwise rotation of the second translating gear 70 will also rotate the collar 72 in a similar direction. The collar 72 will then, upon rotation, cooperates and engage with the drive screw 66 to move the drive screw 66 in a distal manner.
This rotation of the collar 72 allows the drive screw 66 to rotate and move distally. The drive screw 66 rotates and moves in an axial manner through the bore of the second translating gear 70 and the collar in a direction toward and through the endoscopic portion 16 of the surgical stapler 10 . Upon rotation, the drive screw 66 will traverse laterally by rotation into the endoscopic portion 16 a predetermined amount in a direction away from the handle 14 of the surgical stapler 10 to actuate the stapler mechanism. A significant aspect of this embodiment is that the drive screw 66 has a considerable amount of torque from motor 30 in order to translate the force to the staple mechanism and to form the staples against anvil.
FIG. 4A illustrates another embodiment of the surgical stapler 10 . In this embodiment, the motor 30 is shown unconnected from any power supply for illustration purposes. The motor 30 has a drive shaft 32 . The drive shaft 32 is connected to a first bevel gear 31 .
In this embodiment, the motor 30 is disposed at ninety degrees from the drive screw 66 . Upon the actuation of trigger switch 26 ( FIG. 1 ) power will traverse from the battery 29 to the motor 30 ( FIG. 1A ). The energized motor 30 will rotate the motor drive shaft 32 to spin bevel gear 31 . Bevel gear 31 is in contact with second gear 33 that is disposed in concentric fashion with drive screw 66 using member 72 as discussed above.
Bevel gear 31 will rotate drive screw 66 to move the drive screw 66 in a longitudinal manner to actuate one or more other components of the surgical stapler 10 such for tissue compression or for stapling. Bevel gear 31 is useful to change a rotation direction of the motor output shaft 32 to move drive screw 66 longitudinally or distally and proximally, and to orient the motor 30 in an advantageous manner relative to the handle 14 . Bevel gear 31 has teeth that can be straight, spiral or hypoid. Although bevel gear 31 is shown as perpendicular to gear 33 , other arrangements are contemplated. Instead, of bevel gear 31 with second gear 33 oriented as shown the surgical stapler 10 may incorporate a hypoid gear which can engage with the axes in different planes. Hypoid gear may further permit different spacing arrangements of the motor 30 relative to the drive screw 66 to further provide for a more compact, balanced and ergonomic stapler design.
Referring now to FIG. 5 , there is shown a cross sectional view of the endoscopic device 16 . Upon actuation, the drive screw 66 rotates a predetermined distance through a central bore 74 in the endoscopic portion 16 . After traversing the predetermined distance, the drive screw 66 will contact a longitudinal firing member 76 . The longitudinal firing member 76 will then contact a complementary structure to fire the staples in the staple cartridge 21 in the distal region of the surgical stapler 10 as is known in the art. In another exemplary embodiment, of the present disclosure, the drive source 30 may be a reversible drive source. Additionally, the staple cartridge 21 may have one row or multiple rows of staples and the surgical stapler 10 may fire with an amount of torque to easily form staples having the desired configuration.
In this alternative embodiment, the drive screw 66 may reverse automatically or manually to move proximally at the conclusion of the stapling relative to the endoscopic portion 16 . Upon the drive source 30 actuated by the switch 26 or another manual or automatic actuating device, the drive source rotates the drive shaft 32 in the opposite rotational direction. The drive shaft 32 then rotates the first drive gear 68 in the opposite rotational direction. Thereafter, a number of teeth of the first drive gear 66 rotate the second translating gear 70 in the opposite direction. The second translating gear 70 will then rotate the drive screw 66 in the opposite direction to return the drive screw 68 to an initial position for the next stapling operation.
Referring now to FIG. 6 , there is shown another alternative embodiment of the present disclosure. In this embodiment, the jaws 21 , 22 are powered by the drive source 30 . The jaws 21 , 22 may be moved in close alignment with one another to clamp tissue therebetween and be powered by motor or drive source 30 . The surgical stapler 10 has a drive source 30 that has a drive gear 74 being connected to the output drive shaft (not shown) of the motor 30 or drive source. The drive gear 74 is directly connected to the drive source 30 , however alternatively may be connected to the drive source 30 by another gear or by another linkage depending on the space constraints of the handle 14 . The surgical stapler 10 further has a second translation gear 76 . The second translation gear 76 also is connected through the drive screw 66 that drives the drive screw 66 to fire the staple cartridge 21 as discussed previously.
In this embodiment, the lever 24 is connected to the linkage assembly 54 at the intermediate portion 50 of the lever 24 . The lever 24 when lowered from the elevated position, imparts a downward force on the linkage assembly 54 . Thereafter, the linkage assembly 54 fixed at one end by the interior pin 58 rotates about the interior pin and moves the lever 24 in an axial manner. This moves and advances a linkage (not shown) for clamping the tissue. Still further, the member or another component may actuate a timer (not shown) or display to alert the physician/operator to activate the trigger and to initiate the drive source 30 . In still another embodiment of the present disclosure, the clamping may be mechanically connected or linked to the drive source 30 to provide for a powered compression of tissue. In still another embodiment, the clamping can be performed simultaneously with the firing of the trigger handle 26 , and may be powered by the drive source 30 as opposed to independently of firing.
Once the actuation of the drive source 30 occurs, the drive source will turn the drive gear 74 . The drive gear 74 will then directly rotate the second translation gear 76 and the drive screw 66 disposed directly through the bore of the second translation gear. Again, the drive screw 66 will then impart the required axial force to discharge the staples from the staple cartridge 21 in the distal location of the surgical stapler 10 . As mentioned, once the drive screw 66 travels a predetermined distance, the drive screw 66 will actuate the corresponding stapler mechanism to fire the staples in the staple cartridge 21 .
Although shown as an endoscopic surgical stapler, the present drive system may be used with any surgical stapling device known in the art, such as endoscopic surgical stapling devices, a multi-fire GIA surgical stapler, a TA surgical stapling device, and/or any other surgical stapler device known in the art The present instrument may also be used with a single drive surgical stapler that drives both the clamping device of the jaws 21 , 22 and the stapling device.
It should be understood that the foregoing description is only illustrative of the present disclosure. Various alternatives and modifications can be devised by those skilled in the art without departing from the disclosure. Accordingly, the present disclosure is intended to embrace all such alternatives, modifications and variances. The embodiments described with reference to the attached drawing figures are presented only to demonstrate certain examples of the disclosure. Other elements, steps, methods and techniques that are insubstantially different from those described above and/or in the appended claims are also intended to be within the scope of the disclosure. | A surgical stapler has a handle assembly including a stationary handle and a trigger. The stapler also has a drive assembly with a body having a working end and a cam member supported on the working end. The cam member is positioned to translate relative to the anvil to maintain the anvil in the closed position during firing of the stapler. The trigger is operatively connected to a power cell. The power cell is operably connected to a motor of the drive assembly. The manipulation of the trigger actuates the power cell such that the power cell powers the drive assembly to effect translation of the cam member relative to the anvil. The stapler also has a channel for supporting the staple cartridge and the motor of the drive assembly controls the actuation sled supported within the cartridge. The actuation sled urges the plurality of staples from the cartridge when the anvil is in the closed position and in cooperative alignment with the staple cartridge. | 0 |
BACKGROUND OF THE INVENTION
[0001] This invention relates to storage systems, and in particular to storage system management in which failure boundaries are taken into consideration when assigning storage volumes.
[0002] Large area storage systems are now well known. In these systems massive amounts of data are capable of being stored and automatically backed up or replicated at remote locations to provide increased data reliability. In such systems, large numbers of hard disk drives and sophisticated error correction and redundancy technology are commonly employed. The systems generally operate under control of local and remote application software. Hitachi, Ltd., the assignee of this application, provides local replication software known as “Shadow Image,” and provides remote replication software known as “True Copy.” Remote copy techniques for implementation of software such as this are described in U.S. Pat. No. 5,978,890; U.S. Pat. No. 6,240,494; U.S. Pat. No. 6,321,292; and U.S. Pat. No. 6,408,370. Other companies, for example the IBM Corporation, also provide large area storage systems with these capabilities.
[0003] In such systems when backup storage volumes or replication storage volumes are assigned, they are usually assigned by a controller or server which is controlling the storage system. In commercial systems available now, the assignment of such storage volumes to particular groups for functionality as primary storage systems, backup storage systems or replication storage systems is generally done without regard to the potential modes of failure of the storage system itself. This can result in less than optimal performance should failures impact both the primary storage and the secondary storage in certain circumstances. For example, a resulting failure may make it necessary to recopy a large amount of data to another location, delaying use of the primary functionality of the storage system while the extra backup or replication operation is completed. If a particular disk failure occurs, some logical volumes will be impacted. In a conventional storage system, however, the storage controller will not consider the physical layout when it creates a replication pattern. Thus, the physical failure may not only impact the primary volume, but also the replication volumes. The technology described with respect to this invention provides a technique for avoiding this undesirable circumstance.
BRIEF SUMMARY OF THE INVENTION
[0004] This invention provides a technique for improving the replication and backup operations in storage systems to help minimize the impact of failures on more than small portions of the storage system. In some circumstances when a replication volume is assigned into the same failure boundary as a source volume, for example it is assigned to the same error correction group, a single failure may impact both the original volume and the replication volume. In another situation when daily backups are performed, if the storage volume to which the backup operation is assigned falls within the same failure boundary as the source volume, the replication volume will also be impacted. Generally storage systems such as described in this application are robust enough to allow for re-creation of the data, or recopying of the data, to some other replication or primary volume meaning that data will not be lost. An undesirable result of this operation, however, is that the storage system is occupied with such “overhead” functions, impacting the performance of its primary function.
[0005] This invention provides a technique for avoiding this undesirable situation. In particular, according to this invention, in a storage environment, levels of failure boundaries are determined. These failure boundaries are determined by reference to what portion of the storage system will be impacted by a particular failure, for example, susceptibility to an error correction failure, a storage controller failure, a storage volume failure, etc. In a preferred embodiment of this invention those failure boundaries are then collected by management software operating or controlling the overall storage system. This management software may also collect information about the storage environment such as performance and reliability information.
[0006] Once the failure boundary or boundaries are determined, replication volumes are assigned to assure that they cross failure boundaries. In this manner the impact of a failure event within a given failure boundary is minimized. One technique for assigning failure boundaries to achieve this is to use the logical address assignment as the basis for the awareness of the failure boundaries. These logical addresses typically correspond to volume numbers, error correction groups, or other structure of the storage system. For example, logical addresses having 0 as a first digit may be assigned to volumes stored within failure boundary A, while those logical addresses having a 1 as a first address digit may be assigned to storage volumes within failure boundary B. This assignment can be performed manually, or by the system administrator who uses a graphical user interface, or some other appropriate interface, to make the replication configuration determination.
[0007] In a preferred embodiment of the invention a method of controlling a storage system having primary storage volumes and replication storage volumes includes the steps of determining a boundary of a potential failure of the primary storage volumes and the replication storage volumes and using that determined boundary, assigning the replication storage volumes to assure that at least some of them are outside the failure boundary.
[0008] A storage system which implements the invention includes a set of primary storage volumes, a set of replication storage volumes which improve the reliability of the storage system, a memory for storing information regarding at least one boundary of a potential failure of the primary storage volumes and the replication storage volumes, and a controller coupled to the memory for assigning replication storage volumes to assure that at least some of them are outside the failure boundary.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 illustrates a typical storage system configuration;
[0010] FIG. 2 is a block diagram of a VPM server;
[0011] FIG. 3 illustrates a logical view of failure boundaries;
[0012] FIG. 4 illustrates a horizontal addressing layout;
[0013] FIG. 5 illustrates a vertical addressing layout;
[0014] FIG. 6 illustrates failure boundary tables within the VPM server;
[0015] FIG. 7 illustrates a table of pair configuration;
[0016] FIG. 8 is a flow chart illustrating a manual storage management technique;
[0017] FIGS. 9 through 11 illustrate graphical user interfaces performing manual configuration control of the storage system, with each figure illustrating a different embodiment;
[0018] FIG. 12 is a diagram illustrating the graphical user interface for a user group;
[0019] FIG. 13 is a diagram illustrating the policy for a full backup;
[0020] FIG. 14 is a flow chart illustrating a hybrid backup process;
[0021] FIG. 15 is a flow chart illustrating a full backup schedule;
[0022] FIG. 16 is a diagram illustrating a differential backup;
[0023] FIG. 17 is a diagram illustrating a differential backup using vertical storage addressing; and
[0024] FIG. 18 is a diagram illustrating a disaster recovery technique.
DETAILED DESCRIPTION OF THE INVENTION
[0025] FIG. 1 is a block diagram of a storage system. As shown, host 101 and storage subsystem 102 are connected with an input/output interface 111 . Interface 111 can be provided by a fibre channel, ESCON etc. The number of host and storage subsystems 102 is arbitrary. In FIG. 1 a more detailed view of storage subsystem 102 is provided. Subsystem 102 includes a subsystem controller 103 and a disk enclosure 104 . The subsystem controller 103 includes channel controllers 112 , disk controllers 113 , a shared memory 114 and a cache memory 115 . These components are usually configured as a pair, i.e. duplicates of each other. Generally each member of the pair belongs to a different power boundary to provide assurance that a single failure of the power supply does not disable both subsystem controllers.
[0026] Internal connections 116 and 117 connect the two controllers, the shared memory 114 and the cache memory 115 . The shared memory stores control data for the storage system 102 . The cache memory stores data from the host 101 , typically while writing operations are occurring to transfer that data to the storage volumes. Both the shared memory 114 and the cache memory 115 are preferably backed up with battery power in addition to being connected to separate electrical power sources.
[0027] In operation, the channel controller 112 receives an I/O request from the host 101 which it analyzes. Once the analysis is completed, the operation is configured as a job for the disk controller 113 . The internal job is stored in the shared memory 114 . The disk controller 113 issues I/O requests to the disk drives 121 . The disk controller 113 receives the job from the shared memory 114 and issues I/O request to the disk drive 121 . The disk enclosure 104 includes the disk drives 121 which are illustrated in a typical physical layout in FIG. 1 . Host 101 , however, sees only logical volumes, such as logical volume 122 . These logical volumes may span many separate hard disk drives or storage volumes. As is known, error correction groups 123 can be provided to enhance reliability. The error correction groups 123 are usually divided among the logical volumes 122 . The storage subsystem 102 provides some replication methodology among the logical volumes 122 . This replication methodology can include local replication and remote replication. Local replication provides for volume replication within the storage subsystem 102 , while remote replication provides logical volume replication across storage systems 102 . Both techniques help improve the reliability of the overall storage network.
[0028] FIG. 2 illustrates one preferred embodiment of a VPM server 106 . Server 106 is used in management of the storage system shown in FIG. 1 . The server 106 includes a VPM engine 201 , a user interface 202 and a table 203 . To provide the functionality described in conjunction with this invention, a further table known as a group table 204 is also provided. The group table defines levels of groups of failure boundaries. (Failure boundaries are discussed in conjunction with FIG. 3 ). In addition to the failure boundaries, the group table may also include information such as reliability information, performance information, statistical information, etc. As will be described, this information enables the VPM server 106 to configure replication pairs based on the type of storage subsystems, the type of logical volumes, the storage space remaining, etc.
[0029] FIG. 3 is a diagram illustrating failure boundaries in a typical system. Examples of failure boundaries will make this concept clearer. For example, in FIG. 3 the smallest failure boundary 301 is an error correction group. This small boundary may consist of only one (or a few) disk drives, preferably configured in a RAID type configuration. The failure boundary is used to designate that if one of the disk drives 121 in the ECC group 301 fails, all of the other logical volumes which belong to that group 301 will be impacted. Such a failure will require the data to be reconstructed using the error correction information stored across those shared volumes.
[0030] Of course, the concept of a failure boundary can be extended to larger portions of the storage system. For example, all of the error correction groups that happen to be controlled by either one of the controller pair will be impacted if either of the controller pair fail. This failure boundary 302 is also shown in FIG. 3 . In a similar manner, any failure of a controller pair within the storage system will affect the subsystem within which that controller pair is situated. This failure boundary is shown as boundary 303 . As shown in FIG. 3 this concept can be extended to a pool of logical volumes, and in fact, to the complete pool of all volumes.
[0031] Next will be described two major addressing formats—horizontal and vertical. The addressing format, as will be seen, impacts the manner in which failure boundaries are considered. FIG. 4 illustrates horizontal addressing. As suggested by the name, addresses in horizontal addressing are assigned across the storage volumes. In FIG. 4 the primary volume 401 is located in group # 0 . In the illustrated case there are three secondary groups 403 . This will cause the VPM to locate four secondary volumes 402 out of the three secondary volume groups 403 . As mentioned, preferably the groups will cross failure boundaries. The level of the failure boundary will be determined automatically using the system software and an appropriate policy, or the level may be determined by a system administrator. However determined, the level can consist of one error correction group 301 , a controller pair 302 , etc., as discussed above. Once that assignment is complete, the VPM engine 201 selects a volume from each secondary group 403 and assigns it an identification. The first secondary volume S 00 is selected from the first group, the second secondary volume S 10 is selected from the next volume group, while the third secondary volume S 20 is selected from the next volume group. When the VPM engine 201 needs to select the fourth secondary volume it will return back to the storage volume group 1 . In a similar manner primary volume P 1 will have secondary volumes as shown in groups 1 , 2 and 3 in FIG. 4 . In this manner once the VPM engine 201 obtains the physical (internal) allocation, then physical to logical mapping may be completed.
[0032] In the implementation depicted in the figures, SCSI is used as an example. In this circumstance the primary has two volumes in one target A, and there are four copies to be made. In such a case the VPM engine 201 makes the four SCSI targets (B, C, D and E) and will have two secondary volumes in each target. In a fibre channel implementation the SCSI will target B, C, D and E and have two secondary volumes in each target. The system management may simply use targets B, C, D and E to obtain reliable replication. In this manner, if group number 2 fails, only the target C drive will be impacted, and other groups and backup copies will not be affected. Of course protocols other than SCSI may be employed.
[0033] FIG. 5 is a diagram illustrating a vertical addressing layout. In this embodiment the replication volumes are related to each other, for example by being used for incremental backups. As such it is not necessary to use replication volumes across the failure boundary. Thus, in the case of vertical addressing the impact of replication is the same as with example of horizontal addressing; the only differences are the physical arrangement of the storage volumes.
[0034] FIG. 6 is a diagram illustrating some of the tables suitable for use in the server to define various failure boundaries. These tables are typically determined by the VPM engine 201 collecting internal information from the storage system 102 , for example, such as the controller group table 610 and the error correction group table 620 .
[0035] The VPM engine 201 creates an overview of the configuration such as the site group table shown in FIG. 6 a . The site group table employs three levels of groups—site, department and subsystem. The definition of site and department will depend on the environment in which the storage system is situated. A VPM server 106 for an administrator can define these characteristics. Each site will have a site group ID 602 and a site group name 603 . Each department has a department group ID 604 and a department name 605 . Each storage subsystem has a subsystem group ID 606 and a subsystem name 607 . In the site group table 601 shown in FIG. 6 a, the left hand column defines the site group number, with the next column specifying its physical location. The next two columns define a department group ID and a particular department, with the last two columns defining a system group identification and then a subsystem.
[0036] The controller group table, shown in the middle of FIG. 6 , defines the system in terms of its controllers C 0 . . . C 3 and specifies the number of error correction groups associated with each controller. The controller group table 610 and the error correction group table are shown in FIG. 6 as separate tables—as would be done in a relational database. Of course these could be merged to make a conventional flat file database.
[0037] FIG. 6 c depicts an error correction group table, in this example the error correction groups associated with controller C 0 . As shown in FIG. 6 c , controller group C 0 includes error correction groups C 0 E 0 , C 0 E 1 , C 0 E 2 and C 0 E 3 . Group E 0 is implemented by having a storage capacity of 280 gigabytes (of which 100 gigabytes are presently used). The 280 gigabytes is achieved by using multiple 72 gigabyte SCSI, 10,000 rpm hard disk drives. The type of error correction is shown in the right hand column in FIG. 6 c.
[0038] The error correction group table includes detailed information on the error correction groups. The name of the group 621 , the total capacity of the group 622 , the consumed capacity of the group, user 623 , the type of disk drives (type 624 ) and the type of the error correction group 625 are all shown.
[0039] FIG. 6 d is a table illustrating the logical volume configuration table 630 . As shown there, each error correction group includes a logical volume configuration table. The table includes identification of the logical volume ID 631 and a pair ID 633 , which provides identification for the pair which can be used to identify replication pairs.
[0040] FIG. 6 e illustrates a table showing group information. The VPM engine 201 has a capability of making group information such as that shown in Table 6 d . Therein the group ID 641 shows the identifier of the group, which may also correspond to the logical volume. The group type can be a subsystem, controller pair 302 or error correction group 301 . The Name 643 is the name of the group and the capacity 645 is the total capacity of the group. The used capacity corresponds to the capacity of the group that has been used. The reliability 646 is the reliability of the group. For example, it is now known that RAID1 is more reliable than RAID5. In addition performance statistics, for example I/O per second 647 or megabytes per second 648 may also be maintained. These statistics enable evaluation of random workload (I/O) or sequential workload (MB) information.
[0041] FIG. 7 illustrates a configuration of the replication pairs. The pair designation is given in column 701 with the source designation in column 702 and the destination in 703 . The status, whether synchronized or in suspend mode is shown in column 704 . Performance can be stored in column 705 . Using the group to manage replication pairs helps reduce management overhead for the overall system operation.
[0042] FIG. 8 is a flow chart illustrating manual operations for the system. To begin, the administrator provides parameters for replication volumes to the VPM server 106 , as designated by step 801 . The parameters in this example are levels of the failure boundary, addressing, performance, reliability, cost, and emulation of the volume. Then the VPM server 106 checks the parameters to determine if there are enough volumes to satisfy the needed requirements (step 802 ). If the server 106 finds some error in the parameters, or is short of volumes, then an error is reported to the administrator as shown by step 808 . If the parameters are satisfactory, then the server 106 begins creating the replication pairs, as shown by steps 803 to 809 . The VPM server 106 selects volume groups by using the VPM group table 204 , as shown by step 803 . The parameters indicate which failure boundary levels should be used. Usually the failure boundary level is indicated with some range, (for example from the error correction to the subsystem). The particular number of the group does not matter.
[0043] Next the VPM server 106 selects the volumes from the volume groups as shown by step 804 . Here the server 106 uses addressing to indicate horizontal, vertical, or some other form, which is given at step 801 by the administrator. Configuration of the logical volume, emulation type, address from host view, and other information may also be provided. For FC SCSI environment the worldwide name (WWN) and the logical unit number (LUN) are the usual parameters for the address. The configuration of the replication pair indicates the source logical volume ant the destination logical volume.
[0044] If there is any error between steps 803 and step 808 , than the error is reported out by the system and operation otherwise awaits instructions. This is shown by step 808 . On the other hand, if the operations are completed successfully, then the final configuration result is reported out at step 809 .
[0045] It should be noted that this invention does not limit itself to volume level only operations. The operations can be managed instead by a user of application group level. When an administrator presents the system group information and requires group replication, then the VPM server 106 creates the replication volumes for the group.
[0046] FIGS. 9 through 11 illustrate examples of a graphical user interface (GUI) to implement the procedures shown in FIG. 8 . FIG. 9 illustrates an example of a configuration GUI. At first an administrator selects the source volume and begins the replication configuration procedure. This brings up a first window such as that shown in FIG. 9 a . The window preferably contains two kinds of information. One type is information about the source volume, while the second are the parameters for replication volumes. The administrator then selects the parameters, for example reliability 904 , performance 905 , cost 906 and the number of replication volumes 907 . These parameters will be given by the storage subsystem 102 , however, it is generally easy to estimate them from the configuration information. If the administrator would like to use the same group as source volume then the box “same boundary” can be checked.
[0047] The source volume has basic information such as shown in FIG. 9 b . The source information can be an identifier for the logical volume, its type, size, etc. Application and user information can also be employed. The user can be an individual or a group, for example a department. The use of the information is discussed below in conjunction with FIG. 12 .
[0048] FIG. 10 illustrates an example of a GUI used to define a failure boundary. This example shows only one level for the failure boundary (in contrast to the earlier FIG. 3 which showed multiple levels). In the illustration the administrator is selected subsystem level. That provides an indication that there are three controllers in this subsystem which is the same system as the source logical volume. The table also indicates that there are 60 logical volumes in the subsystem. If desired, the VPM server 106 can provide the recommended boundary with the administrator having a capability of overriding that information.
[0049] FIG. 11 is an example of the GUI 1101 for group selection and addressing 1102 . The administrator has the capability of reviewing the details by clicking one of the detail buttons. As before, the VPM server 106 can indicate the recommended set of the configuration with the administrator being provided override capability. Following this window the VPM server 106 will select logical volumes from the selected group. And appropriate addressing may be chosen by the user.
[0050] FIG. 12 is another GUI to illustrate user group information 1201 and application information 1210 . Here the source volume can have the same basic information 1202 / 1212 and the same replication policy 1203 / 1213 . Both will have almost the same details. In this illustration “NAME” indicates the name of the user or application. “ID” is the identifier of the user application. “TYPE” is the type of source logical volume, while replication requirements are specified by “RELIABILITY,” “PERFORMANCE,” and “COST.” The replication policy 1203 / 1213 indicates the policy for the particular replication operation. Pre-definition by the policy administrator may eliminate the need to customize each logical volume. For some implementations, it may be easier to use a template for the policy. This will enable the template to contain information describing not only-the reliability, performance and cost, but also schedule, mixture of different types of volumes, etc.
[0051] There are different policies that can be made for the daily backup operation. The first type, simply backing up daily to another storage volume uses conventional replication approaches. Another type, hybrid backup, uses a different approach and is shown in FIG. 13 . The policy of the hybrid backup has sub-policies referred to as a daily backup policy and weekly backup policy. The daily backup policy can be implemented at high speed and low cost. To obtain the lower costs, the administrator may define remote operations to occur to low cost subsystems such as ATA disk drive based storage subsystems. These conditions can be changed to suit the particular customer environment. For example, in this case, six backups are taken from each day of the week from Monday to Saturday, and destination volumes will be within the same subsystem, but at different or across a different error correction group. To obtain reliable backups, preferably horizontal addressing is employed. A weekly backup can be taken on Sunday with high reliability. In this circumstance the failure boundary is defined across the subsystem.
[0052] FIG. 14 is a flowchart diagram illustrating a schedule of the hybrid backup. The backup is taken at an indicated time, for example, midnight or later. In conjunction with this, the procedure shown in FIG. 14 is started. At first the VPM server checks the schedule (daily of weekly). If it is a daily backup then the server takes a backup with a daily backup policy. The replication volume will be selected as across the failure boundary. If horizontal addressing is employed, then server 106 only selects the next volume, 1401 or 1403 . On the other hand if a weekly backup is to be taken then the backup was made with a daily backup policy 1401 , 1402 . In this case the VPM server 106 will take the backup to a selected volume 1404 .
[0053] During the backup, if the replication pairs are synchronized, the backup can be taken by simply splitting the pair with a suspend command if the pair is not synchronized, then the pair will need to be resynchronized. Afterward the pair is split by the VPM server 106 .
[0054] FIG. 15 illustrates a schedule for a daily backup. The VPM server 106 uses the same type of volume for each daily backup as shown by steps 1501 and 1502 .
[0055] FIG. 16 is a diagram illustrating differential backup. The differential backup uses two kinds of volumes. One is a full backup volume which is replicated over a long period, for example once a week. This full backup will be the same as the source volume. Based on the source volume, the differential backups make small differential backups every so often, for example daily. Usually the differential backup makes differential data based on the full backup. The differential data does not need the same types of volumes as the source volume, so, for example, lower cost or slower hard disk drives may be employed.
[0056] Often the backup software will make a full backup and a differential backup. In this case the stored subsystem has the capability of taking the full backup. Thus, some backup software can collaborate with the storage backup capability. FIG. 16 illustrates a policy for the differential backup. The policy A consists of two policies. One is a daily backup B, the other is the weekly backup C. For the daily backup B, the VPM server 106 does need to prepare a volume. The same volume as the source volume is necessary to prepare a high reliability volume, and thus, the policy requires middle levels of reliability. In addition, the volume is not related to the replication. A differential backup can be recovered without previous differential backup by using the full backup.
[0057] An incremental backup operation uses two kinds of volumes. One is a full backup volume which is replicated over the long period mentioned above. This full backup will be the same as the source volume. Based on this volume, incremental backups are made on a short period, for example daily. Use of the incremental backup makes a differential data based on previous differential backups or full backups available. The incremental data does not need to use the same type of volumes as the storage volumes. As mentioned, usually the backup software will make a full backup and an incremental backup. In such cases the software often has the capability of collaborating with the storage backup capability.
[0058] FIG. 17 is a diagram illustrating a policy for an incremental backup. The policy A consists of two policies. One is a daily backup B and the other is the weekly backup C. For the daily backup B, the VPM server 106 does not need to prepare the same volume as the source volume. It is not necessary to have a high reliability volume, instead a middle level reliability may suffice.
[0059] The preceding has been a description of preferred embodiments of the method and apparatus for copying and backup and storage systems in which failure boundaries are used to improve reliability. Although specific configurations and implementing technology have been described, it should be understood that the scope of the invention is defined by the appended claims. | A technique is described for controlling a storage system in which primary storage volumes and replication storage volumes are present. A boundary of a potential failure of the primary storage volumes and the replication storage volumes is determined, and using that boundary, replication storage volumes are assigned to assure that at least some of them are outside the failure boundary. | 6 |
FIELD OF THE INVENTION
[0001] The present invention pertains to an aircraft cabin ventilation system that uses the momentum of a jet of air ejected from a nozzle to draw cabin air through a filter or other device to sanitize the air before returning it to the cabin, thereby increasing the total apparent ventilation rate to the cabin without enlarging the ventilation system of the aircraft. In particular, the present invention pertains to a ventilation system that employs a plurality of nozzles positioned in a cavity between a sidewall of the aircraft cabin and a section of the aircraft fuselage. The nozzles receive a supply of ventilation air and direct jets of air from the cavity and into the aircraft cabin, with the jets of air creating low pressure areas in the cavity. Ventilation openings in the cabin sidewall communicate the low pressure areas with the cabin interior, whereby the low pressure areas draw air from the cabin interior into the cavity where the drawn air is entrained into the jets of air produced by the nozzles. Devices inside the cavity remove suspend impurities from the air drawn into the cavity. In this manner, the ventilation system of the invention filters or sanitizes the air drawn through the system and thereby increases the total apparent ventilation rate to the aircraft cabin without enlarging the ventilation system of the aircraft.
BACKGROUND
[0002] Commercial aircraft set up for the transportation of passengers typically include rows of seats along the length of the aircraft cabin. Because the primary purpose of this type of commercial aircraft is to transport passengers, the aircraft cabin is usually set up to maximize the number of seats in the cabin. However, increasing the number of seated passengers in the aircraft cabin also increases the potential for the transfer of microorganisms or other air suspend impurities between the passengers in the aircraft cabin.
[0003] The potential problem of airborne disease or other air suspended impurities in the cabin of an aircraft is mitigated by dilution ventilation. The removal of microbials from the breathing space of an aircraft cabin reduces the risk of airborne infection. Current disease models suggest that some benefit is obtained by increasing the flow of pathogen free air to the aircraft cabin. Current ventilation air distribution systems provide between 15 and 25 cfm per passenger in economy seating. The ventilation air distribution systems are flowing at the maximum capacity of the ducting of the system and the system fans. Thus, the limited capacity of current air distribution systems in passenger aircraft is a primary problem in reducing the risk of airborne infection.
[0004] One solution is to reduce the passenger count, thereby increasing the ventilation flow per person. However, reducing the passenger count is not a popular solution because it drives up the cost of the airline ticket proportionately, wastes fuel, and causes flight delays through the increased aircraft traffic resulting from reducing the number of passengers in each aircraft.
[0005] Ultraviolet light sterilizers irradiating ventilation air are very effective in providing pathogen free ventilation air. However, exposing the passengers to the radiation of ultraviolet light is not acceptable.
[0006] Filter material, for example felt, could be added to the air ventilation distribution system to remove air suspended impurities. However, in warm, high humidity environments the filter material would absorb moisture from the cool ventilation air, thereby becoming a source of bacterial growth. Additionally, the wet filter material could present the problem of condensation dripping on passengers during open door loading in the humid environment.
SUMMARY
[0007] The aircraft of the present invention is provided with an apparatus that reduces the transfer of air suspended impurities in a cabin of an aircraft without increasing the capacity of the existing air distribution system of the aircraft.
[0008] The apparatus includes a housing that is positioned in a cavity between a sidewall of the aircraft cabin and a section of a fuselage of the aircraft. The housing has an interior volume that communicates with the cabin interior through an air return opening in the sidewall of the cabin and an air outlet opening in the sidewall of the cabin.
[0009] A ventilation air supply duct extends from the source of ventilation air of the aircraft, through the cavity between the cabin sidewall and the section of the fuselage of the aircraft and to the housing. The ventilation air supply duct is connected to the housing and communicates a supply of ventilation air to the housing interior.
[0010] At least one nozzle is positioned in the housing interior. The nozzle is connected in communication with the ventilation air supply duct and receives the ventilation air communicated by the supply duct. The nozzle is constructed to produce a jet of air from the ventilation air received. The nozzle directs the jet of air through the housing interior, through the air outlet opening in the cabin sidewall and into the cabin interior. The jet of air from the nozzle also creates a low pressure area in the housing interior.
[0011] The air return opening in the sidewall of the cabin communicates the cabin interior with the low pressure area in the housing interior. The low pressure area in the housing interior draws air from the cabin through the air return opening and into the housing interior. The air drawn into the housing interior is entrained into the jet of air directed from the nozzle and flows with the jet of air through the housing interior and back into the cabin interior.
[0012] A device in the housing interior removes air suspended impurities from the air drawn into the housing interior through the air return opening. The device can be a filter, a germicidal lamp, or a combination of both.
[0013] A condensation drain is also provided on the housing of the apparatus. The drain allows any moisture that drips from a filter employed in the housing and/or any water that condenses from the cold ventilation air supplied to the nozzle in warm, high humidity environments to drain from the housing.
[0014] In the above manner, the apparatus of the invention increases the total apparent filtered ventilation air to the aircraft cabin without enlarging the ventilation system of the aircraft.
[0015] The features, functions, and advantages that have been discussed can be achieved independently in various embodiments or may be combined in yet other embodiments further details of which can be seen with reference to the following description and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 is a representation of a cross-section view of an aircraft employing the apparatus of the invention showing the opposite outboard sidewalls of the aircraft cabin and the cavity between the cabin sidewalls and exterior sections of the aircraft fuselage.
[0017] FIG. 2 is a representation of an enlarged view of the apparatus of the invention shown in FIG. 1 .
[0018] FIG. 3 is a representation of a perspective view of the apparatus.
[0019] FIG. 4 is a representation of a perspective view of the apparatus similar to that of FIG. 3 , but showing the apparatus disassembled.
[0020] FIG. 5 is a representation of the flow paths of primary airflow through the apparatus and entrained airflow through the apparatus.
DESCRIPTION
[0021] The aircraft of the present invention is provided with an apparatus that reduces the transfer of air suspended impurities in a cabin of an aircraft without increasing the capacity of the existing air distribution system of the aircraft.
[0022] FIG. 1 is a representation of a cross-section view of a typical aircraft employing the cabin air entrainment filtration system with a condensation drain of the apparatus of the invention. The aircraft 12 is basically comprised of a floor having a floor surface 14 , and cabin sidewalls 16 , 18 extending around opposite sides of the aircraft cabin interior 22 . Sections of the aircraft fuselage 24 , 26 extend around the respective sidewalls 16 , 18 and enclose cavities 28 , 30 between the sidewalls 16 , 18 and the sections of fuselage 24 , 26 .
[0023] The existing ventilation system of the aircraft 12 includes a source of ventilation air 32 represented schematically in FIG. 1 . The source of ventilation air 32 provides a flow of cool ventilation air to the aircraft cabin interior. The flow of ventilation air is supplied from the air source 32 to air flow ducts 34 , 36 that extend through the cavities 28 , 30 between the respective cabin sidewalls 16 , 18 and the exterior sections of the aircraft fuselage 24 , 26 . The flow of ventilation air from the source of ventilation 32 can be driven by one or more fans or other equivalent means currently employed in aircraft. Typically, the flow of ventilation air is directed through a plurality of ducts 34 , 36 and into the cabin interior 22 through a plurality of air outlet openings in the cabin sidewalls 16 , 18 just below the stowage bins 38 , 40 of the aircraft. It should therefore be understood that although only a pair of ducts 34 , 36 are shown in FIG. 1 extending through the respective cavities 28 , 30 in the laterally opposite sides of the aircraft 12 , the source of ventilation 32 could be providing flows of cool ventilation air through pluralities of similar ducts that are spatially arranged in the cavities along the longitudinal length of the aircraft.
[0024] To simplify the description of the apparatus 44 , the apparatus will be described in association with only one of the air ducts 34 that extends through the cavity 28 between the cabin sidewall 16 and the aircraft fuselage section 24 . It should be understood that the apparatus 44 can be employed with each of the plurality of air ducts 34 , 36 positioned in the cavities 28 , 30 between the respective cabin sidewalls 16 , 18 and the aircraft fuselage sections 24 , 26 . Thus, a plurality of the apparatus would be positioned along the cavities 28 , 30 .
[0025] FIG. 1 shows the positioning of the apparatus 44 relative to the aircraft 12 . The apparatus 44 is positioned in the cavity 28 between the cabin sidewall 16 and the aircraft fuselage section 24 . The apparatus 44 is positioned vertically in the cavity 28 adjacent a passenger breathing zone 46 of the cabin interior. The breathing zone 46 is approximately the height of a passenger's head above the floor surface 14 when seated in the aircraft.
[0026] FIG. 2 shows an enlarged view of the apparatus 44 positioned to the left in FIG. 1 . It should be understood that the apparatus 44 positioned to the right in FIG. 1 is a mirror image of that shown in FIG. 2 .
[0027] Referring to FIGS. 2 , 3 and 4 , the apparatus 44 includes a housing 52 positioned in the cavity 28 between the cabin sidewall 16 and the aircraft fuselage section 24 . The housing 52 has a large lower portion 54 . The lower portion 54 has a general elongate cube configuration defined by lower portions of laterally spaced first 56 and second 58 sidewalls of the housing, lower portions of longitudinally spaced first 62 and second 64 end walls of the housing and a bottom wall 68 of the housing. The bottom wall 68 has a drain hole and a drain tube 70 extending downwardly from the bottom wall. The housing also has a smaller upper portion 66 that extends upwardly from the lower portion 54 . As the upper portion 66 extends upwardly the first 56 and second 58 sidewalls of the housing merge toward each other and form the housing upper portion 66 as a narrow flue with a rectangular cross-section. The housing upper portion 66 at first extends straight upwardly from the housing lower portion 54 , but then bends through a curve as it extends to an air outlet opening 72 at the opposite end of the housing upper portion 66 from the housing lower portion 54 . As shown in FIGS. 1 and 2 , the air outlet opening 72 of the housing 52 is positioned in the cabin sidewall 16 just below the stowage bin 38 of the aircraft cabin and communicates an interior volume 74 of the housing 52 with the cabin interior 22 .
[0028] A drawn air inlet opening 76 is provided through the first sidewall 56 of the housing 52 . The drawn air inlet opening 76 has, for example a rectangular configuration and occupies much of the first sidewall 56 . A filter 78 can be positioned in the drawn air inlet opening 76 . The filter 78 would provide a device for removing airborne impurities in air drawn into the housing interior 74 through the drawn air inlet opening 76 in a manner to be explained. Alternatively, the apparatus 44 could be employed without the filter 78 .
[0029] An air return opening 82 is provided in the aircraft cabin sidewall 16 adjacent the drawn air inlet opening 76 of the housing 52 . The air return opening 82 can be covered with a decorative grill, with louvers, overlapping fins or slats or other equivalent types of ventilating openings 84 that allow air to pass through the openings but block the view of a passenger in the cabin interior 22 into the cavity 28 .
[0030] A ventilation air inlet opening 86 is provided in the first end wall 62 of the housing 52 . As shown in the drawing figures, the ventilation air inlet opening 86 is positioned in the first end wall 62 toward the top of the lower housing portion 54 where the lower housing portion begins to merge into the upper housing portion 66 . The ventilation duct 34 extending through the cavity 28 is connected to the first end wall 62 of the housing 52 at the ventilation air inlet opening 86 . In this manner, the source of ventilation air 32 communicates through the duct 34 with the housing interior 74 and supplies a flow of air through the duct 34 and the ventilation air inlet opening 86 to the housing interior 74 .
[0031] A hollow diffuser tube 92 extends longitudinally through the housing interior 74 . Opposite ends of the diffuser tube 92 are connected to the opposed interior surfaces of the first end wall 62 and the second end wall 64 of the housing. The hollow interior 94 of the diffuser tube 92 communicates through the ventilation air inlet opening 86 in the housing first end wall 62 with the ventilation air duct 34 connected to the housing. As seen in the drawing figures, the diffuser tube 92 is straight and extends straight through the housing. Other equivalent configurations of the diffuser tube could be employed other than that shown. With the diffuser tube 92 communicating with the ventilation air inlet opening 86 , the diffuser tube 92 is positioned toward the top of the housing lower portion 54 just where the housing lower portion begins to merge into the housing upper portion 66 . A plurality of holes extend through the top of the diffuser tube 94 and communicate the interior of the diffuser tube with the housing interior 74 . The plurality of holes form nozzles 96 that are spatially arranged in a straight line across the top of the diffuser tube 92 and are directed upwardly toward the center of the housing upper portion 66 . With all of the nozzles 96 directed upwardly through the housing upper portion 66 , when a flow of ventilation air from the ventilation air source 32 is directed through the duct 34 and the ventilation air inlet opening 86 into the interior of the diffuser tube 92 , the nozzles 96 direct jets of the air upwardly through the interior of the housing upper portion 66 and out through the air outlet opening 72 of the housing into the cabin interior 22 . The jets of air directed from the nozzles 96 create a low-pressure area 98 in the housing interior 74 toward the bottom of the housing lower portion 54 on an opposite side of the diffuser tube 92 from the nozzles. This low-pressure area 98 in the housing interior 74 communicates through the drawn air inlet opening 76 of the housing and the air return opening 82 of the cabin sidewall 16 to draw air from the cabin interior 22 into the low-pressure area 98 of the housing. This air drawn into the housing interior 74 is then entrained into the flow of air produced by the jets of air from the nozzles 96 and travels through the housing upper portion 66 and the housing air outlet opening 72 and is returned to the cabin interior 22 .
[0032] Referring to FIG. 2 , a device 102 is provided in the housing interior 74 that removes air suspended impurities from the air drawn into the housing interior through the drawn air inlet opening 76 of the housing and the air return opening 82 of the cabin sidewall 16 . The device 102 could be an additional filter, a germicidal lamp, or a combination of both. In the embodiment of the apparatus shown in FIG. 2 the device 102 is an ultraviolet light sterilizer that irradiates the air drawn into the low-pressure area 98 of the housing through the housing drawn air inlet opening 76 and the air return opening 82 in the cabin sidewall 16 . The ultraviolet light destroys microbials and other impurities carried by the air drawn into the low-pressure area 98 of the housing interior that penetrates the filter 78 , or pass through the drawn air inlet opening 76 when a filter is not employed. The ultraviolet light 102 is positioned in the housing interior 74 where the light cannot pass through the louvers or other equivalent mechanisms of the air return opening 82 in the cabin sidewall 16 and subject passengers to the ultraviolet light or enable the ultraviolet light to be seen by passengers.
[0033] Thus, the apparatus 44 described above reduces the transfer of air suspended impurities in the aircraft cabin interior 22 . Referring to FIG. 5 , when a flow of air is supplied from the source of ventilation air 32 through the ducting 34 to the nozzles 96 in the housing interior 74 , the nozzles produce jets of air 104 directed from the nozzles into the housing upper portion 66 , through the housing air outlet opening 72 and into the aircraft cabin interior 22 . The jets of air 104 produced by the nozzles 96 also create an area of low pressure 98 in the housing lower portion 54 . The area of low pressure 98 draws air 106 from the cabin interior 22 through the air return opening 82 in the cabin sidewall 16 , through the drawn air inlet opening 76 in the housing 52 and into the low-pressure area 98 of the housing 52 . The air 106 drawn into the low-pressure area 98 is irradiated with ultraviolet light from the ultraviolet light sterilizer 102 . The irradiated air 108 is then entrained and mixed with the jets of air 104 from the nozzles 96 and returned with the jets of air to the cabin interior 22 .
[0034] In the above manner, the apparatus of the invention increases the total apparent filtered ventilation air to the aircraft cabin without enlarging the ventilation system of the aircraft.
[0035] As various modifications could be made in the constructions of the apparatus and the methods herein described and illustrated without departing from the scope of the invention, it is intended that all matter contained in the foregoing description or shown in the accompanying drawings shall be interpreted as illustrative rather than limiting. Thus, the breadth and scope of the present invention should not be limited by any of the above described exemplary embodiments, but should be defined only in accordance with the following claims appended hereto and their equivalents. | An aircraft has a ventilation system that employs a plurality of nozzles positioned in a cavity between a sidewall of the aircraft cabin and a section of the aircraft fuselage. The nozzles receive a supply of ventilation air and direct jets of air from the nozzles, through the cavity and into the aircraft cabin. The jets of air produced by the nozzles create low-pressure areas in the cavity. At least one return air opening in the cabin sidewall communicates the low-pressure areas with the cabin interior, whereby the low pressure areas draw air from the cabin interior into the cavity where the drawn air is entrained with the jets of air produced by the nozzles. Devices inside the cavity remove suspended impurities from the air drawn into the cavity. In this manner, the ventilation system filters or sanitizes the air drawn through the system. | 1 |
BACKGROUND OF THE INVENTION
(1) Field of the Invention
The present invention relates to a method of drying honeycomb structural bodies in which a dielectric drying is performed by moving the honeycomb structural bodies in a dielectric drying apparatus under a condition such that vapor is flowed in the dielectric drying apparatus.
(2) Prior Art Statement
Generally, when the honeycomb structural body formed from a batch containing water component is dried, a dielectric drying utilizing the dielectric drying apparatus is performed. Specifically, a dielectric drying is performed by moving the honeycomb structural body in the dielectric drying apparatus as follows. That is, the honeycomb structural body is set on a carrier in such a manner that one end portion of the honeycomb structural body is contacted to a surface of the carrier, and the carrier is moved under a condition such that vapor is flowed in the dielectric drying apparatus so as to prevent a cutout defect of an outer wall.
The method of drying the honeycomb structural bodies utilizing a known dielectric drying mentioned above is sufficient for drying the known honeycomb structural body with no defects in which a thickness of a rib is relatively thicker or in which a size (outer diameter, length) is small. However, in the case that a thin wall honeycomb structural body having a rib thickness of for example 2 mill or less, that is recently required, is dried, a so-called rib twist defect, in which the rib is not generated straight at the end portion of the honeycomb structural body as shown in FIGS. 2 and 3, occurs frequently. If such a rib twist defect is generated, a strength of the honeycomb structural body is decreased, and it is not possible to obtain normal honeycomb structural bodies. Therefore, it is desired to develop a technique for preventing the rib twist defect.
SUMMARY OF THE INVENTION
An object of the present invention is to eliminate the drawbacks mentioned above and to provide a method of drying honeycomb structural bodies in which defects such as rib twist and so on are not generated during a drying operation even if a thin wall honeycomb structural body is dried.
According to the invention, a method of drying honeycomb structural bodies in which a dielectric drying is performed by moving the honeycomb structural bodies in a dielectric drying apparatus under a condition such that vapor is flowed in the dielectric drying apparatus, comprises the steps of: covering a surrounding area of the honeycomb structural body by a sheet with a constant space; and performing the dielectric drying under such a condition.
In the present invention, since the surrounding area of the honeycomb structural body is covered by the sheet with a constant space during the dielectric drying operation, it is possible to increase humidity around an outer wall of the honeycomb structural body, and a wind flowing in the dielectric drying apparatus is not directly contacted to the outer wall. Therefore, a drying of the outer wall can be slow, and drying speeds at the outer wall and at inner portion of the honeycomb structural body are substantially same. In this manner, a drying balance of the honeycomb structural body can be achieved, and thus it is possible to prevent the defect generation such as rib twist and so on during the drying operation.
As a preferred embodiment of the present invention, there are following features such that: a Teflon® fluorocarbon resin sheet is used as the sheet; a dielectric drying is performed under a condition such that additional electrodes are set directly to both end portions of the honeycomb structural body on the carrier of the dielectric drying apparatus; and the space between the honeycomb structural body and the sheet is set to 20 -30 mm. In all the preferred embodiments mentioned above, it is possible to prevent the rib twist defect more effectively, and thus they are the preferred embodiments.
BRIEF DESCRIPTION OF THE DRAWING
For a better understanding of the present invention, explanations are made to the following drawings wherein:
FIG. 1 is a schematic view for explaining one embodiment of a method of drying honeycomb structural bodies according to the invention;
FIG. 2 is a schematic view for explaining one embodiment of a defect in the known method of drying honeycomb structural bodies; and
FIG. 3 is a schematic view for explaining another embodiment of a defect in the known method of drying honeycomb structural bodies.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 is a schematic view for explaining one embodiment of a method of drying honeycomb structural bodies according to the invention. In FIG. 1, a state only near honeycomb structural bodies in a dielectric drying apparatus is shown. In the embodiment shown in FIG. 1, a numeral 1 is a honeycomb structural body, and a numeral 2 is a carrier for setting an end portion of the honeycomb structural body 1 thereon, which is constructed so as to be movable in the dielectric drying apparatus. Moreover, in this embodiment, a lower additional electrode 3 is arranged between a lower end surface of the honeycomb structural body 1 and the carrier 2 , and an upper additional electrode 4 is arranged on an upper end surface of the honeycomb structural body 1 .
The honeycomb structural body 1 to be dried according to the drying method of the invention is obtained by extruding a ceramic batch such as for example cordierite by utilizing a die. Since the batch contains a large amount of water component, a water control of the honeycomb structural body is performed by drying it before sintering so as to be able to sinter the honeycomb structural body. Moreover, in the embodiment shown in FIG. 1, a cross section of the honeycomb structural body 1 is circular shape, but use may be made of the honeycomb structural body 1 having a cross section of race track shape, oval shape and so on. As to the cross sectional shape, since a rib twist defect is easily generated in the honeycomb structural body 1 having cross sections other than circular shape, the present invention can be applied more effectively for such honeycomb structural bodies 1 . Further, vapor (not shown) is flowed in the dielectric drying apparatus.
A feature of the method of drying honeycomb structural bodies according to the invention is that a surrounding area of the honeycomb structural body 1 is covered by the sheet 5 with a constant space and the dielectric drying is performed under such a condition. As the sheet 5 , since a temperature during the drying operation is about 100° C., use may be made of any sheets even if they have a heat resistance for this temperature. However, it is preferred to use Teflon® fluorocarbon resin. The sheet 5 made of Teflon® fluorocarbon resin has a low dielectric constant and thus it is not easily self-heated. Therefore, it has a sufficient heat resistance for that temperature. Moreover, a reason for using the sheet 5 is that the sheet 5 can be applied flexibly even if the honeycomb structural body has any cross sectional shapes.
The space between the honeycomb structural body 1 and the sheet 5 is not particularly limited since a preferred range is varied in accordance with a size of the honeycomb structural body 1 . However, in the honeycomb structural body 1 having a diameter of 100-150 mm that is used normally, it is preferred to set a space 6 to 20-30 mm so as to increase humidity around near the outer wall of the honeycomb structural body 1 . Moreover, in the embodiment shown in FIG. 1, the lower additional electrode 3 and the upper additional electrode 4 are arranged to the both end portions of the honeycomb structural body 1 , and an efficiency of dielectric drying is increased as compared with the dielectric drying apparatus in which the additional electrodes are not used. However, it is a matter of course that the present invention can be applied effectively to the dielectric drying apparatus in which the additional electrodes 3 and 4 are not used.
In the embodiment shown in FIG. 1, an actual dielectric drying operation can be performed as follows. That is, the honeycomb structural body 1 after forming is firstly set on the lower additional electrode 3 mounted on the carrier 2 . Then, a surrounding area of the honeycomb structural body 1 is covered by the sheet 5 with a constant space. In this case, it is preferred to set a height of the sheet 5 equal to or a little lower than that of the honeycomb structural body 1 so as not to be an obstacle for the upper additional electrode 4 when it is set on the upper end portion of the honeycomb structural body 1 . Under such a condition, the honeycomb structural body 1 is moved in the dielectric drying apparatus, in which vapor is flowed, by moving the carrier 2 . In this manner, the dielectric drying operation can be performed.
In the present invention, the space 6 is formed between the outer wall of the honeycomb structural body 1 and the sheet 5 during the dielectric drying operation, and an atmosphere having a high humidity is maintained in the space 6 in accordance with drying of the honeycomb structural body 1 . In this case, it is possible to maintain a humidity of an atmosphere in the space 6 equal to or higher than that of an inner atmosphere of the dielectric drying apparatus. Therefore, a drying speed near the outer wall of the honeycomb structural body 1 can be made slow as compared with the case in which the sheet 5 is not arranged. Moreover, a wind is flowed in the dielectric drying apparatus, but this wind is not directly contacted to the outer wall of the honeycomb structural body 1 since the wind is interrupted by the sheet 5 . As a result, it is possible to achieve substantially same drying speeds both at the outer wall and at the inner portion of the honeycomb structural body 1 .
As clearly understood from the above explanations, according to the invention, since the surrounding area of the honeycomb structural body is covered by the sheet with a constant space during the dielectric drying operation, it is possible to increase humidity around an outer wall of the honeycomb structural body, and a wind flowing in the dielectric drying apparatus is not directly contacted to the outer wall. Therefore, a drying of the outer wall can be slow, and drying speeds at the outer wall and at inner portion of the honeycomb structural body are substantially same. In this manner, a drying balance of the honeycomb structural body can be achieved, and thus it is possible to prevent the defect generation such as rib twist and so on during the drying operation. | A method of drying honeycomb structural bodies in which a dielectric drying is performed by moving the honeycomb structural bodies in a dielectric drying apparatus under a condition such that vapor is flowed in the dielectric drying apparatus, includes the steps of: covering a surrounding area of the honeycomb structural body by a sheet with a constant space; and performing the dielectric drying under such a condition. | 5 |
BACKGROUND OF THE INVENTION
The present invention relates to a method and apparatus for treating a permeable web material with a fluid. The fluid may be used for displacement washing of the web, it may be a reactive material such as a bleach or dye, or it may be some other type of treatment.
A number of different generic types of apparatus are known for treatment of woven or non-woven webs with various fluid materials. One very common type is the vacuum drum. Here a web of material is run onto the porous surface of a drum and fluid is flowed onto the material from external showers. Vacuum boxes or other means for creating a reduced pressure within the drum draw the fluid through the web. Alternatively, the web may be formed on the drum from a slurry of fibrous material prior to treatment. One or more press rolls may bear against the drum to assist in fluid removal. An alternative but similar form of apparatus uses a shroud enclosed drum which is pressurized on the outside. In this case the pressure is generally quite low, typically in the range of 15 to 30 kPa. In another type of treatment apparatus the web is held between two fluid permeable parallel wires supported on or between a series of small diameter press rolls. Fluid can be showered on the web between the press rolls.
To show some specific examples of apparatus for treating permeable webs, Sando et al., U.S. Pat. No. 4,277,860, show a woven cloth carried between opposing fluid permeable belts immersed in a treating fluid. Staggered opposing nozzles placed under the fluid and outside the belts spray hot fluid onto both surfaces of the cloth as it passes through the fluid bath.
Lintunen et al., U.S. Pat. No. 4,292,123, show a washer for a continuous web of cellulose pulp. The pulp is formed into a wet sheet or mat on a simple forming wire prior to contacting the outer surface of a fluid permeable rotating drum. The drum is surrounded by a plurality of washing stations which are spaced a sufficient distance from the drum surface to accommodate the pulp web. Washing fluid is introduced, preferably in countercurrent fashion, where it then flows through a foraminous surface in the washer stations, through the pulp, and then into a collection zone into the interior of the drum.
Walsh, U.S. Pat. No. 3,199,317 shows a fabric or similar material being carried on a moving endless belt having a concave portion dipping into a pool of treating fluid. The fabric emerges from the bath and passes, while still on the belt, between a pair of rollers that squeeze out excess fluid.
Winch, U.S. Pat. No. 4,199,966, show a web being carried on an endless perforated belt through a tank of fluid. A series of rollers are placed alternately above and below the belt so that it travels a somewhat sinuous path. As the web on the belt passes under a roller it is lightly squeezed. As the belt passes over the adjacent roller the web expands. Fluid may be passed through the tank in countercurrent fashion to effect washing or other treatment.
Many of the devices just described, while being well suited for some specific purpose for which they were designed, have serious shortcomings when used with other materials or for different types of treatments. Among these shortcomings are the need for large quantities of treating fluid, with attendant expensive collection and pumping equipment, and discharging a treated mat which is still very wet and contains a large amount of entrained treating fluid.
My earlier U.S. patent application, Ser. No. 849,931, filed Apr. 8, 1986, is hereby incorporated by reference. There are certain common features shared by the pressing device of the earlier application and my present apparatus which is used for treatment of a permeable mat with a fluid. The earlier described device is not suitable for the latter purpose without the major modifications and improvements now to be described.
SUMMARY OF THE INVENTION
The present invention relates to a method for continuously treating a permeable web with a fluid and to an apparatus for carrying out the treatment. The apparatus comprises a rotatable drum having a fluid permeable endless belt reeved about at least a portion of the drum circumference. At least two spaced-apart press rolls bear against the outer surface of the belt pressing it against the drum with sufficient force to form nip zones. A belt position control mechanism gives the belt limited freedom of radial movement away from the drum in the area between nip zones. This permits a gap of controllable dimension to form between the drum and the belt. The gapped region defines a volume which comprises a permeable web treating zone. The drum surface is provided with at least one row of spaced-apart apertures located entirely around the circumference of the drum. These apertures are in communication with a fluid supply system which can supply treating fluid under pressure outwardly through the surface apertures into the treating zone between the press rolls. In order to prevent fluid leakage along the belt margins it is necessary to provide seals which act between the edges of the belt and the drum. A conventional driving mechanism for the belt and/or drum completes the basic apparatus.
In operation a fluid permeable web of the material to be treated is continuously passed between the moving belt and rotating drum. Treating fluid under pressure is directed outwardly through the drum apertures against the drum facing surface of the web as it passes through the treating zone. The treating zone itself becomes pressurized and the run of belt between the press rolls reacts against the pressurized treating fluid to retain the pressure. This pressure causes the belt to assume a catenary-like configuration between the press rolls with the height of the catenary being determined by the belt position control mechanism. The gap must be sufficiently large to permit a pool of fluid to form between the web and drum when the web is forced against the belt by the pressure of the treating fluid. Formation of this pool is essential since it permits both lateral and circumferential flow of the treating fluid and assures uniform contact between the treating fluid and the entire surface of the mat contained within the treatment zone.
The treating fluid may be water, steam, air, bleaching chemical, dye, or any liquid or gas appropriate to the specific treatment being carried out.
In a preferred form the apertures on the drum surface will be provided with a check valve mechanism to prevent back flow of treating fluid into the supply lines.
Either a single row or a plurality of rows of apertures may be provided on the drum surface. Normally a single row is all that is necessary since a pool of fluid under the mat being treated provides for simple, uniform distribution of the fluid from a minimum number of apertures in the drum surface.
Within a treating zone there is normally little or no contact between the mat and the drum surface except at the nip zones at either end of the treating zone. This absence of mechanical contact permits the web to expand. The expansion normally increases web permeability, and it also permits the web to take up more fluid. The increased permeability reduces pressure drop across the web and permits more fluid to pass through the web at a given treating fluid pressure. The increased fluid flow and mat/fluid contact enhances the operation being carried out whether it is washing, chemical reaction, or some similar treatment.
It is within the scope of the present invention to use only two spaced-apart press rolls and create a single treatment zone or a plurality of press rolls to create a number of sequential treatment zones. In the latter case it will often be desirable to provide a mechanism for collecting expressed fluid from one treatment zone to recycle or return it to another treatment zone to provide either concurrent or countercurrent treatments. In either case the treating fluid is normally supplied to the drum apertures through a rotary valve. This valve may be segmented in known fashion to supply treating fluid to the treating zones.
Where the treatment zone encompasses more than half of the circumference of the drum it is possible for the drum to be free floating and supported solely by the press rolls acting through the belt. In one version of the invention two adjacent press rolls, one at each end of the treating zone or zones, may be made relatively translatable a limited distance toward or away from each other to control belt position.
The endless belt may be supported in part by rolls spaced away from the drum that do not create nip zones. Alternatively, it may be supported entirely by the press rolls. In this case, as has been just described, two of the press rolls are relatively translatable. These serve the dual service of providing nip zones and controlling belt position. Where the drum is free floating the distance between these position control press rolls must always be less than the diameter of the drum. Further, the nips zones formed by these press rolls divide the drum circumference into major and minor portions with the major portion encompassing more than 180° of angle. At least one additional idling press roll is located adjacent the drum along the major portion of the drum circumference between the two belt position control press rolls. A single idling press roll will create two treatment zones between the position control press rolls. In similar fashion, each additional press roll will create an additional sequential treatment zone. The drum must have freedom of movement so as to maintain full contact with both belt position control rolls at any time when the distance between them may be changed. Also, the idler press roll or rolls must be free to move radially with respect to the drum so as to maintain full contact against the drum during such movements. In a construction of this type all of the press rolls serve the further function of maintaining belt spacing within the belt loop. An outer portion of the belt loop will continually exert a radially directed force on the idler press rolls. This force maintains idler press roll pressure at its contact point where it forces the inner run of the belt loop against the drum surface. Optionally, a supplementary mechanism may be used in concert with the idler press rolls to increase the nip force over and above that provided solely by belt tension.
It is an object of the invention to provide an apparatus for continuously and effectively treating a permeable web with a fluid.
It is another object to provide an apparatus as described which creates web treatment zones between a rotating drum and a moving belt spaced away from the drum.
It is a further object to provide a treatment apparatus in which treatment zones are defined between a moving belt and rotating drum between spaced-apart press rolls which create nip zones between belt and drum.
It is still another object to provide an apparatus of the type described having a plurality of sequential treatment zones.
It is yet a further object to provide an apparatus of the type described in which the drum may be made free floating to simplify mechanical construction.
It is an additional object to provide a method for treatment of a fluid permeable web using an apparatus of the type described in which web treatment zones are created between a rotating drum and movable belt.
These and many other objects will become readily apparent to those skilled in the art upon reading the following detailed description taken in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a representational side elevation view of one embodiment of the treating apparatus.
FIG. 2 is a section taken along line 2--2 of FIG. 1.
FIG. 3 is a section taken along line 3--3 of FIG. 1.
FIG. 4 is a partial sectional view of a suitable rotary supply system for treating fluid.
FIG. 5A is a section taken along line 5--5 of FIG. 4 showing a stator suitable for two-stage fluid treatment.
FIG. 5B is a section taken along line 5--5 of FIG. 4 showing a stator suitable for one-stage fluid treatment.
FIG. 6 is a section taken along line 6--6 of FIG. 4 showing a rotor element for the liquid distribution system.
FIGS. 7 and 8 are sections similar to that of FIG. 2 showing alternative embodiments of marginal belt seals.
FIG. 9 is a partial sectional view in side elevation showing an alternate form of drum surface intended to reduce fluid flow from the nip zone into the treating zone.
FIG. 10 is a fragmentary sectional view in side elevation showing one check valve system for preventing reverse flow of treating fluid.
FIG. 11 is a fragmentary sectional view taken along line 11--11 of FIG. 10.
FIG. 12 shows an alternative check valve system.
FIG. 13 is a fragmentary sectional view taken along line 13--13 of FIG. 12.
FIG. 14 is a representational side elevation view of a two-stage treating apparatus using a free floating drum.
FIG. 15 is a diagrammatic illustration showing sequential treatment of a web using two of the devices of FIG. 14 in series.
FIG. 16 is a diagrammatic illustration showing two stage treatment of a web using recycled fluid in a device of the type shown in FIG. 14.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Reference should now be made to the figures which will now be described in detail. One form of the treatment apparatus, seen in FIG. 1, is generally indicated at 10. This consists of a centrally located rotary drum 12 running on shaft 14 which is journalled in a pillow block bearing 16. The bearing is supported on a frame member 18 which is indicated only in fragmentary form to simplify the drawing. An endless fluid permeable belt 20 is reeved about the drum. This belt is supported on fixed idler rolls 22, 26, 30 which are, in turn, journalled in bearings 24, 28, 32 attached to the frame. A fourth idler roll 34 serves as a belt position control roll. This is held in bearing 36 which, in turn, is attached to frame 18 through a position control device 38. Nip rolls 40, 46 are included within the belt loop. These are held respectively in bearings 42, 48 and are connected to any conventional device for applying force directed along a drum radius, as is indicated by directional arrows 44, 50. The nip rolls create nip zones 52, 54 where they press belt 20 against drum 12. Belt position control roll 34 must be adjustable so that the loop of belt 56 reeved around drum 12 can form a gap of dimension d with the drum and create a volume 58 which serves as a treating zone. In operation the run of belt 56 reeved about drum 12 between nip or press rolls 40, 46 assumes a catenary-like configuration if it is not reeved around more than 180° of drum circumference. The distance d of the gap between the catenary configured belt and drum 12 is controlled by the position of control roll 34. A web 60 being treated, shown here in phantom form, passes into the treating zone 58 at nip zone 52 and emerges from the treating zone at nip zone 54.
Reference to FIG. 4 shows a simplified longitudinal section through the drum in which the shaft or trunnions 14 are omitted. A rotary joint, generally indicated at 70, is in communication with a supply of treating fluid through duct or pipe 82. The rotary joint consists of a stator 72 and rotor 74. The rotor, in turn, communicates with distribution pipes 76 which run to orifices 80 passing through the drum surface. A check valve or seal assembly 81 prevents back flow of treating fluid into the supply line.
FIGS. 5A and 5B show versions of the rotary joint useful respectively for two-stage and single-stage treatment. In FIG. 5A the stator member 72' has ducts 83 connecting with orifices 84, 88 emptying into milled distribution slots 86, 90. In this case each of the two treatment zones will cover 90° of drum surface. It will be understood that a plurality of treating fluid supply ducts 82 could be used so that different fluids could be supplied to distribution slots 86, 90 as, for example, would be necessary for a countercurrent type of treatment. The version shown in FIG. 5B has only a single fluid distribution duct 83 opening into orifice 92 into distribution slot 94. In this version of the device the treatment zone will encompass 180° of drum surface. Rotary valves of this type are conventional and, per se, form no part of the present invention.
FIG. 6 is a cross section through line 6--6 of FIG. 4 and shows rotor section 74 containing fluid ingress orifices 96 and a plurality of spoke-like radial distribution ducts 76 connected to orifices 80 passing through drum shell 12. This portion of the device is essentially the same regardless of whether the apparatus is configured for only one or for multiple treatment stages as long as there is at least one distribution duct 76 in communication with each treatment zone at all times.
FIGS. 2, 3, 7, and 8 show various sectional views and optional configurations of the web treating apparatus in operation. In FIG. 2 the mat 60 being treated lies between drum 12 and belt 20. The mat is shown here pressed against the drum-facing surface of belt 20 leaving a gap 62 between the drum-facing surface of mat 60 and drum 12. In the illustration gap 62 is filled with treating fluid and represents a pool of fluid underlying the mat over substantially the entire treatment zone except for the areas immediately adjacent the press or nip rolls. Position control roll 34 must be adjusted to permit this pool to form. Otherwise, there will not be a uniform distribution of treating fluid under the mat.
FIG. 3 shows the mat as it passes beneath the upper nip roll 40. Here the mat is compressed and forms a barrier against fluid passing out of the treating zone between the mat and the drum.
In FIGS. 2 and 3 belt 20 is shown abutting flanges 13 on the edge of roll 12. It is essential that this or some other kind of marginal seal is present to prevent loss of treating fluid from the edges of the belt. If this loss occurred to any extent it would be unacceptable and the apparatus would not work as intended. FIGS. 7 and 8 are similar to FIG. 2 but show other forms of marginal seals. In FIG. 7 a resilient seal 100 is affixed to the edges of belt 20 and serves to present a larger area for blocking fluid loss against flange 13. A somewhat different arrangement is shown in FIG. 8 where seal 102 is a separate member seated in grooves 104 machined in the edges of drum 12. No flanges are required on the drum in this case. This type of seal is well suited for the treatment of thin webs using small overall gap dimensions. Other types of edge seal arrangements will be readily apparent to those skilled in the art.
FIG. 9 shows a modified drum surface in which drum 12 has a regular series of raised ridges or corrugations 106. These ridges serve to reduce the flow of treating fluid from the nip zone back into the treating zone as web 60 passes through nip zone 54. Preferably these ridges are essentially equidistantly spaced and located parallel to the longitudinal axis of the drum.
It is desirable to have a check valve mechanism associated with orifices 80 to prevent any backflow of treating fluid into the supply source. This could potentially occur as the drum and treated web pass through one of the nip zones. FIGS. 10-14 show two simple and effective mechanical arrangements which serve the function of check valves. In FIG. 10 a resilient belt or spring-like member 110 is attached circumferentially around the drum overlying the mouths of orifices 80. This resilient member may be attached in a number of ways. In the present case bolts or similar fastening means 112 with washers 114 serve to attach resilient member 110 to the drum. This construction is shown in cross section in FIG. 11. It should be noted that the representation pictured in FIG. 10 presumes that the drum is passing through a treating zone and that fluid pressure, exerted by the treating fluid emerging from the orifice 80, has raised resilient member 110 away from the drum to permit passage of fluid into the treating zone.
A somewhat different and preferred configuration is shown in FIGS. 12 and 13. Here the resilient member 118, serving as a check valve, is retained within a channel or groove 119 formed in the surface of roll 12. This channel preferably has sloping side walls 120 which will more readily permit the passage of treating fluid when the resilient member 118 is lifted by fluid pressure. As is seen in FIG. 12 member 118 is pressed tightly against and acts as an effective seal for orifices 80 as the assembly passes through a nip zone 54.
A somewhat different configuration of the mat treatment device is shown in FIG. 14. Here there are no idler rolls within the belt loop other than those which also serve as press rolls to create nips with the drum. In this version a fixed press roll 121 and a movable press roll 126, spaced some distance from it, serve the dual function of belt position control and drum support. Position control press roll 121 is journalled in bearing 122 which may be anchored to frame member 124. Belt position control roll 126 is journalled in bearing 128. Bearing 128 rides on track 130 anchored to frame 124. The position of roll 126 can be adjusted with respect to that of roll 121 by translating it a limited distance with a translating mechanism 136 operating through a connecting rod 138. Translating mechanism 136 is very conventional and can be a fluid cylinder, a rack and pinion or similar gear arrangement, or other well known means. It should be considered within the scope of the invention to have a similar mechanism on roll 121 so that both rolls are moved simultaneously and equidistantly. Drum 12 may be shaftless and ride in free floating fashion on press rolls 121, 126 if the spacing between these rolls is limited to a distance less than the drum diameter. At least one additional press roll must be provided. In the present example idling press roll 132 is journalled in bearing 134. This is mounted on a lever arm 140 in turn connected by a bearing 142 and pin 144 to frame member 124. Roll 132 must be free to move radially with respect to drum 12 if the position of the drum should change due to variation in distance between the belt position control rolls 121 and 126. In similar fashion, drum 12 must itself be free to adjust position. It is for this reason that a free-floating drum is a preferred configuration.
Belt 20 is configured into a closed loop with an outer run 164 generally having the configuration of a triangle and an inner run 166 generally in the configuration of the Greek letter Ω. The belt loop itself has an outer face 165 and an inner face 167. Outer face 165 is reeved around the drum 12 while all of the press rolls 121, 126, 132 are enclosed within the belt loop and in contact with inner face 167. The rolls create three nip zones which, in turn, define two treatment zones 62, 63. A web of material 60 is shown passing around drum 12 and through the two treatment zones.
FIG. 16 shows diagramatically how the apparatus could be used for two stage countercurrent or concurrent treatment of a web using expressed fluid from one treatment zone which is returned to the other treatment zone. The drum 212 has a fixed press roll 221 and a moveable press roll 226. An idling press roll 232 is mounted above and between them. The belt is not shown in this figure and it is presumed that the device to this point is identical to the one shown in FIG. 14. An appropriate state of the art fluid collection hood 280 is mounted over the treatment zone between rolls 226 and 232 and a similar hood 284 is mounted over the treatment zone between rolls 221 and 232. Fluid expressed from the first of these treatment zones is collected by hood 280 and directed into a holding tank 282. From there it is returned by pump 286 to the second treating zone. Hub 274 is appropriately modified to handle the two liquid streams.
The gap between the belt and the drum in the treatment zones is controlled by the relative position of press rolls 121 and 126. As the rolls move relatively further apart the gap is increased whereas the gap is narrowed if the spacing between the rolls is decreased.
The fluid supply system for the drum and the belt margin seals are similar or identical to those described for the configuration shown in FIGS. 1, 7, or 8.
One advantage of the configuration shown in FIG. 14 is its simplicity of construction. No additional idler rolls are used other than those which also serve as nip rolls forcing the belt into contact with the drum. Further, the fact that the drum is free-floating simplifies drum construction. The drum is not subject to axial bending loads, therefore, it can be of relatively lighter construction. The machine frame construction is also simplified. Drum position can be readily maintained by well known means such as rollers acting against the edges. Conventional means are also available for assuring proper belt tracking.
Materials of construction will depend entirely on the use for which the apparatus is intended. For some applications, such as applying bleaching chemicals to the web of material, corrosion resistant metals or plastics may be needed. In this case the belt is preferably a fabric mesh made of nylon or similar durable plastic material. Belts of this type are available from a number of manufacturers. One such manufacturer is the Appleton Wire Division of Albany International, Appleton, Wisconsin. Where corrosion is not a problem, it may be desirable to use a wire mesh belt. Belts of this type are also available from a number of vendors of which the Maryland Wire Belt Company, Church Creek, Md. is an example. The above vendors are mentioned only as examples and not in any way as an endorsement of their products over those available from other manufacturers.
It is evident from reference to FIG. 14 that considerable pressure will be placed on idling nip roll 132 by the outer run 160 of the belt loop. Additional nip force can be gained by further loading idler press roll 132 by means of a fluid cylinder 146 acting through piston rod 148 and connecting link 150.
It should be considered within the scope of the invention to use generally similar units of the present apparatus in sequence so that a web may be discharged from the treating zone of a first apparatus and, without significantly altering its integrity, pass into the treating zone of a second apparatus.
FIG. 15 is illustrative of an arrangement of this type where identical treatment apparatuses 170, 170', of the type shown in FIG. 14, are used in series. Any of the other embodiments shown could be used in the same manner. In another variation the web may be used as a filter medium to remove particulate material from the treating fluid. The web to be treated may be drawn from a broad variety of materials formed in different manners. They may be fabrics or felts formed of natural or synthetic fibers which have been either dry-formed or wet-formed. The only requirement of the webs is that they possess sufficient integrity to remain in web form as they pass into and through the treating apparatus.
Many variations over and above those described in the examples will be readily apparent to those skilled in the art. It is the inventor's intention that the scope of the invention be limited only by the appended claims. | The invention is a method and apparatus for treating a permeable web with a fluid. The apparatus has a rotatable drum with a fluid permeable endless belt reeved about at least a portion of the drum circumference. Two or more spaced-apart press rolls bear against the outer surface of the belt, pressing it against the drum with sufficient force to form nip zones. A belt position control mechanism gives the belt limited freedom of radial movement away from the drum in the area between the nip zones. This permits a gap of controllable dimension to form between the drum and the belt. The gapped region defines a volume which creates a permeable web treating zone. The drum surface has at least one row of spaced apertures located entirely around its circumference. These apertures communicate with a fluid supply system which can supply treating fluid under pressure outwardly through the surface apertures into the treating zones between the press rolls. Seals between the edges of the belt and the drum prevent fluid leakage along the belt margins. A conventional driving apparatus completes the apparatus. In use, the web of material being treated is passed between the moving belt and rotating drum. Treating fluid under pressure is directed outwardly through the drum apertures against the drum facing surface of the web as it passes through the treating zone. | 3 |
TECHNICAL FIELD
The present invention relates to inhalation devices. Specifically, the present invention relates to inhalation devices capable of dispensing an aerosol medication by way of a breath activated mechanism.
BACKGROUND ART
There are a variety of inhalation devices which release aerosol medication, in a continuous spray or in a metered dose or predetermined amount of medication, directly into the patient's mouth. Typically, these devices were activated by the pressured actuation of the user's fingers, button action, or other related manual techniques, although some are activated by the inhaling action of the user. Heretofore, no simple cheap disposable reliable breath activated devices were developed, and consequently no breath activated devices have reached the market.
Measured dose aerosol canisters of the medicine to be inhaled into the lungs are manufactured in standard sizes by a variety of pharmaceutical companies. These aerosols are much the same as normal aerosol cans, except that when the nozzle pin is depressed, continuous spray does not result; instead a short spray releases a fixed amount of medicine. The spray stops until the nozzle pin is released and depressed again. Currently, these aerosols are used with manually activated inhaler devices that mix atmospheric air with the sprayed medication, permitting a complete breath of air by the patient with his medicine. Aerosol medicines are also available in continuous spray aerosols which continually spray as long as the nozzle pin is depressed.
Proper use of these manual activated devices requires that the spray be activated at the beginning of the breath, so that all the medicine is carried to the lungs as required, and not left in part in the mouth, throat, or spray device, where it is useless. If not all the medicine reaches the lungs, then it is difficult to determine the size of pulmonary dose actually received, and how big a "make up" dose is needed. Over-dosage can be as big a problem as under-dosage. Hence, the timing of the spray activation is critical to proper medication.
Inhalation drug delivery to the lungs is commonly used by asthmatics. Asthma tends to strike small children and old people. These age groups often have bad coordination and weak hands, which can be worsened by the onset of the asthma attack. Hence, the timing of the breadth spray of medicine can be a difficult problem for the people who need it. Heretofore, there has been a frustrated need for a simple disposable device that automatically activates the specific dose medicine spray canisters at the very start of the inhalation on the device.
The prior art teaches a variety of devices to administer medicine to the lungs by spraying while inhaling, but they are manually activated and not activated by the inhalation activity. As a result, these devices do not solve or address the timing or coordination problem with such sprays.
U.S. Pat. No. 3,776,227, issued to Pitesky, et al, on Dec. 4, 1973, discloses a device whereby a cartridge containing gas under pressure is opened by a pin which results in a flow of released gas. The opening is activated by manually rotating a housing containing a pressurized container and valve-supported head relative to one another until the cartridge is punctured U.S. Pat. No. 3,326,231, issued to Hogg, on June 20, 1967, discloses a fluid regulating valve mechanism whereby the flow rate of a fluid released from a puncturable storage container which is ultimately inhaled by the user is metered by regulating the size of the needle valve formed when the pin pierces the container. This process is started by manually depressing an actuator so that the pin will pierce into the compressed container. U.S. Pat. No. 3,045,671, issued to Updegraff, on July 24, 1962, discloses a device whereby a cartridge containing gas under pressure is pierced by a hollow pin or needle which releases a gas which is ultimately inhaled by the user. The piercing of the pressured capsule containing the gas is performed by manually screwing the pin into the cartridge as sealed. U.S. Pat. No. 3,012,694, issued to Johnston, on Dec. 12, 1961, discloses a gas dispensing device whereby gas contained in a pressurized container is released when a point punctures the container. A hand wheel manually operates a threaded member which moves the capsule closer to the point which eventually punctures the container. A sleeve may manually be moved to restrict the opening of the hole and thus regulate the flow of gas to be inhaled. U.S. Pat. No. 1,693,730, issued to Schroeder, on Dec. 4, 1928, discloses a device whereby the quantity of air inhaled corresponds to the depth of the users's breathing. There are no pins or piercing devices needed to dispense a predetermined amount of gas. The flow of the compressed gas creates a vacuum or partial vacuum which draws medicament into the device by droplets. These are then driven into the nozzle and eventually inhaled in a fine spray.
The prior art teaches a limited number of breath activated medication spray devices, but heretofore none are simple, cheap, disposable and reliable.
U.S. Pat. No. 3,636,949, issued to Kropp on Jan. 25, 1972, discloses a device whereby inhaling of a device causes a diaphragm to activate a complicated system of springs and levers, depressing the nozzle pin of an aerosol can, causing the aerosol to discharge into the user's mouth. This device attempts to accomplish a noble purpose, but fails. First, it does not function as intended. The same action that causes the diaphragm to activate the aerosol also opens a vent to allow air to enter the device, breaking the low pressure behind the diaphragm, robbing the diaphragm of its power. Secondly, the diaphragm must generate the considerable power necessary to depress the nozzle pin. (This is distinguished from the instant invention which uses a diaphragm only to generate the power necessary to slide a pin over a hole.) Third, the Kropp invention uses a complicated collection of levers and springs, which makes it big, heavy, expensive, and not cheap or disposable. Fourth, the Kropp device requires a lateral spray cap to come with its aerosol, and the standard medicinal aerosols on the market today do not have such a cap.
U.S. Pat. No. 3,812,854 issued to Michaels, et al on May 28, 1974, and U.S. Pat. No. 4,106,503 issued to Rosenthal and French on Aug. 15, 1978, both use ultrasonic nebulizers attached to respirators to allow medication to be inhaled. These devices are expensive, large electronic devices, are not cheap pocket sized and disposable, and make no use of the standard aerosol medicines on the market today.
U.S. Pat. No. 4,648,393, issued to Landis and Kassey on Mar. 10, 1987, is a "breath-activated medication spray" that attempts to address the timing and coordination problem. This device attempts to accomplish a noble purpose, but has several deficiencies. First, it is not necessarily inhalation activated. It must be manually cocked before it can work at all. When the batteries become weak or dead, its timing is first thrown off and then it stops functioning completely. In addition, this device can be inadvertently activated by jiggling or turning upside down. Secondly, it is a relatively large, heavy, and cumbersome device to use. Thirdly, the manufacture of the device is complicated and expensive and it cannot be made cheaply enough to be disposable, since it has two springs, batteries, a solenoid, an electrical timing switch, a moving magnet, and various electrical wirings. This device cannot be used by a person laying face up on his or her back. Furthermore, it is configured to spray, not directly into the inhalation nozzle, but onto the side wall of a breathing tube. As a result, this device encourages inaccurate dose dispensing since it is unpredictable how much of a dose will adhere to the side of the tube.
The present invention, on the other hand, is distinguishable from the prior art on many points. It is solely and reliably activated by the start of an inhalation. The present invention requires no manual cocking, and requires no batteries or power source. The present invention cannot be activated by jiggling. In its physical embodiment, the present invention is small, light, and simple to use. The present invention can be made out of molded plastic, with only one moving part. As a result, the present invention is cheap and can be used as a disposable dispenser. The present invention can be used in any orientation to the direction of gravity or in a weightless state. The present invention can be used on a patient in any position or while moving. The present invention can also be configured to spray directly out of its mouth nozzle without spray being forced onto the wall of the breathing cavity. It can be used in a mechanized respirator or an unconscious patient. It uses commonly available aerosol medicine spray cans, of measured dose or continuous spray.
It is an object of the present invention to provide an inhalation device that is truly activated by the inhalation of the user.
It is another object of the present invention to provide an inhalation device that is small, light, and simple to use.
It is still a further object of the present invention to provide an inhalation device that can administer a dosage of a medication at the very beginning of the inhalation.
It is still another object of the present invention to provide an inhalation device that can be used in any orientation.
It is still another object of the present invention to provide an inhalation device that minimizes the number of moving parts so as to be cheap to make and hence disposable.
It is an object of the present invention to be used in a mechanical respirator on an unconscious patient.
It is an object of this invention to use commonly available aerosol spray cans of medicine.
These and other objects and advantages of the present invention will become apparent from a reading of the attached specification and appended claims.
SUMMARY OF THE INVENTION
The present invention is an inhalation device for dispensing a medicament to a patient from a dispenser. The present invention comprises a body having an outwardly extending nozzle, a receptacle formed within the body for receiving the dispenser, and an activator positioned within the body that is mechanically interactive with the inhalation of a patient. The activator causes the dispenser to pass the medicament outwardly through the nozzle. The inhalation device also includes a vent that is formed in the body for carbureting air into the nozzle upon the inhalation by the patient. The present invention also includes a fixator that is detachably fastened to the body for affixing the dispenser in proper position within the receptacle.
The fixator comprises a vent formed in the body for allowing air to pass into the receptacle and out through the nozzle. This vent permits less than a free flow of air into the nozzle. The fixator is specifically a cap that is threadedly connectable to the body. This cap has an interior area that contains the dispenser. In general, the cap covers the receptacle of the body. The cap is threaded into a position in which the dispenser is in a dispensing mode within the receptacle.
The activator is responsive to a drop in air pressure within the nozzle. This activator causes the dispenser to release the medicament upon the reduction in air pressure within the nozzle. Specifically, the activator comprises a diaphragm positioned within the body. This diaphragm is deformable upon a reduction in air pressure within the nozzle. The activator also includes a pin that is fixedly positioned within the diaphragm and extends upwardly transverse to the plane of the diaphragm. This pin acts as a valve between the dispenser and the nozzle. The pin is attached to the diaphragm such that a deformation in the diaphragm causes a longitudinal movement in the pin. Specifically, this causes the pin to move longitudinally away from the dispenser. The diaphragm may form a portion of the outer surface of the body. This diaphragm flexes inwardly into the body upon a drop in air pressure within the nozzle.
The body comprises an atomizer positioned between the receptacle and the nozzle. This atomizer opens to the nozzle such that fluid is dispersed into the nozzle. The activator means acts as an air-responsive valve between the receptacle and the atomizer. Specifically, this air-responsive valve has a first position that prevents the passage of the medicament into the atomizer from the dispenser and a second position that allows the passage of such medicament into the atomizer.
The receptacle comprises a plurality of vanes formed in the receptacle. This plurality of vanes creates aerodynamic turbulence that assists in the atomizing of the medicament in the receptacle prior to the medicament reaching the atomizer.
A perforated plug is attached to the body adjacent the diaphragm. This perforated plug is arranged so as to shield the diaphragm from external contact.
The present invention may further include, in an alternative embodiment, a first tube that is connected to the body such that the vent communicates with the interior of the first tube. A second tube is connected to the nozzle of the body. The second tube allows for the transmission of aerosol medication to a location distal of the body. The present invention also may include a timer that is fastened to the body adjacent to the activator. This timer is for selectively restricting the activation of the activator. The timer specifically includes a clock mechanism for measuring time and for setting preset time intervals and an abutment member that is interactive with the clock mechanism. The abutment member is aligned with the pin on the diaphragm. This abutment member is selectively movable between a position abutting the pin and a position distal this pin. The movement of the abutment member is regulated by the clock mechanism. The diaphragm of the activator may also be modified so that it is deformable and moves the attached pin upon an increase in air pressure within the nozzle.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the exterior of the inhalation device of the present invention.
FIG. 2 is a cross-sectional view, in side elevation, of the body of the present invention.
FIG. 3 is a frontal view showing the activator/diaphragm of the present invention.
FIG. 4 is a side view showing the activator/diaphragm of the present invention.
FIG. 5 is a cross-sectional view, in side elevation, showing the configuration of the inhalation device of the present invention prior to inhalation.
FIG. 6 is a cross-sectional view, in side elevation, of the inhalation device of the present invention during inhalation.
FIG. 7 is a diagrammatic illustration showing an alternative embodiment of the inhalation device of the present invention.
FIG. 8 is a cross-sectional view, in side elevation, showing an alternative embodiment of the present invention utilizing a timer mechanism in conjunction with the activator mechanism of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1, there is shown a perspective view of the inhalation device 1 of the present invention. Specifically, inhalation device 1 is an automatic inhalation activated medication spray device. Inhalation device 1 comprises body 1a, nozzle 2, fixator 3, vents 4, and activator 5. The specifics of the interior configuration of the inhalation device is detailed in FIGS. 2, 5, and 6.
It can be seen that body 1a has a generally cylindrical configuration. Body 1a is a hand held mechanism of relatively small size. Body 1a may be manufactured of a metal or may be manufactured from a plastic. It is the intent of the present invention to provide a disposable inhalation device 1. Therefore, in the preferred embodiment of the present invention, the body 1a should be molded of a plastic material.
Nozzle 2 extends outwardly from body 1a. Nozzle 2 has an outer surface 2a that is integrally connected to the exterior of body 1a. The opening 2b of nozzle 2 communicates with the interior of body 1a. Nozzle 2 should have a suitable size for insertion into the mouth of the user. Ideally, the inhalation device 1 of the present invention will cause a fluid within a dispenser within fixator 3 to spray through body 1a to pass outwardly through nozzle 2 and into the mouth of the user.
Fixator 3 is threadedly connected to the top of body 1a. Fixator 3 serves to maintain the aerosol medication spray dispenser therewithin. As such, fixator 3 is a cap having a sufficient interior volume to contain the dispenser. In addition, fixator 3 will cover the open top of body 1a. When the fixator 3 is threaded into the position illustrated in FIG. 1, the dispenser contained therewithin (not shown) will be in a dispensing mode. Vents 4 are formed in the top surface 4a of fixator 3. Vents 4 allow air to pass into the interior of body 1a and outwardly through opening 2b of nozzle 2. Vents 4 should have quality sufficient to restrict the air flow into the interior of body 1a. Although a certain amount of air flow is restricted, it is necessary that air flow be achieved so as to provide for the proper carburetion effects of the present invention. Although the vents 4 are illustrated as located on the top surface 4a of fixator 3, it may be also possible to incorporate the vents 4 elsewhere on the body 1a or into the threaded portion between the body 1a and the fixature 3. The illustration of FIG. 1 is for the purpose of illustrating the need for the vents, rather than a specific requirement of the present invention.
It can be seen that the activator 5 is affixed to the bottom portion of body 1a of inhalation device 1. The specifics of the activator 5 are not illustrated in FIG. 1. FIG. 5 shows that the mechanism is attached to the bottom of the body 1a. Additionally, as described in an alternative embodiment of the present invention, the ring 5 may also be a timer mechanism that can be incorporated so as to prevent continuous usage of the inhalation device 1.
FIG. 2 is a cross-sectional view of the body 1a of inhalation device 1. Initially, it can be seen that the nozzle 2 extends outwardly from the cylindrical surface 4b of body 1a. Nozzle 2 includes the cylindrical walls 2a which encompass the opening 2b. As such, aerosol sprayed fluids will be dispersed through nozzle 2 and outwardly through the end 2c of nozzle 2.
FIG. 2 also shows the receptacle 6 for the receipt of the aerosol dispenser therein. Receptacle 6 has a roughly cylindrical configuration that will conform to the size of the aerosol dispenser. The forward area 7 of the receptacle 6 is a molded area that is formed specifically for the receipt of the nozzle of the dispenser. Specifically, walls 6a extend downwardly and somewhat inwardly so as to join nozzle receptacle walls 6b. Bevelled edges 8 of walls 6b receive and depress the nozzle of the aerosol dispenser. Forward area 7 is a rather tubular area that generally matches the nozzle of the aerosol dispenser. An atomizer outlet 9 is formed in walls 6b so as to allow the fluid to be dispersed, in atomized fashion from interior area 7a outwardly through atomizer 9 and into the area of nozzle 2. A slideway 10 for the pin of the activator (to be described hereinafter) is formed within walls 6b. This is a tubular pathway of rather smooth configuration that allows an easy passage of a pin therein. Opening 10a is formed on the lower portion of wall 6b so as to allow the activator pin easy entry into slideway 10.
Shoulders 11 are formed as inner indentations within the body 1a. The shoulders 11 are formed of the interior of body 1a so as to abut the edges of the diaphragm (to be described hereinafter).
A plurality of turbulence ribs (or vanes) 12 are formed within the forward area 7 of the receptacle 6. In use, these vanes create turbulence to assist in the atomization of the sprayed medicament prior to reaching atomizer 9.
FIG. 3 is a frontal view of the activator/diaphragm 13. Activator/diaphragm 13 is an elastic member of circular configuration. Activator/diaphragm 13 should have an elasticity suitable for permitting deformation in the presence of an inhalation by the user of the inhalation device 1. The circularity of activator diaphragm 13 is of a sufficient size to fit within the area defined beneath the shoulders 11 of the body 1a. Pin 14 is fixed to the middle of diaphragm 13. Pin 14 is of a type suitable for insertion into the opening 10b and into the slideway 10 of the receptacle walls 6b.
FIG. 4 is a side view of the activator diaphragm of FIG. 3. Specifically, it can be seen that the diaphragm 13 has a relatively narrow configuration. The pin 14 is fastened to and extends through the diaphragm 13. Pin 14 generally narrows at its end 14a so as to accommodate its positioning within sideway 10. Pin 14 extends through diaphragm 13 to end 14b. End 14b will be located beneath the diaphragm in its assembled configuration in the inhalation device 1. End 14b may act as an abutment surface when the present invention is utilized in conjunction with a timing device (to be described hereinafter).
FIG. 5 is similar to FIG. 2, except that it shows the diaphragm 13 and the activator pin 14 as utilized within the inhalation device 1. The configuration, illustrated in FIG. 5, is the configuration of the present invention in the absence of an inhalation. As can be seen in FIG. 5, the diaphragm 13 is not deformed. The walls of diaphragm 13 extend straight outwardly and generally near the abutment surface of shoulders 11. It can be seen that the pin 14 extends upwardly through slideway 10. The upper portion 14a of pin 14 extends through the slideway 10 and is in interference relationship with the atomizer opening 9. As such, the configuration illustrated in FIG. 5 acts as a block to the passage of fluid, or gas, into and through nozzle 9. For the purposes of illustration, until upper portion 14a of pin 14 is moved away from the opening of the atomizer 9, no gas, or fluid, can pass outwardly to the user.
FIG. 6 is similar to FIG. 5, except that it shows the diaphragm 13 as flexed in response to reduced pressure within nozzle 2. It can be seen that the specific flexure of the diaphragm 13 causes the walls 13c of diaphragm 13 to flex upwardly into the opening 13d within body 1a. In other words, the suction in nozzle 2 forces these portions 13c of the diaphragm 13 upwardly. Such deformation of these portions 13c of diaphragm 13 work to cause the lower portion 13b of diaphragm 13 to move downwardly. As a result, pin 14 is also drawn downwardly. The upper portion 14a of pin 14 slides downwardly and serves to open atomizer 9. It can also be seen that the diaphragm 13 is now in abutment with the shoulders 11 of body 1a. Such abutment assists in the deformation of the diaphragm 13 and results in the action described hereinbefore.
Spray enters nozzle 2 from the aerosol dispenser 21. Aerosol dispenser 21 is a type of dispenser that can be commonly purchased for use by asthmatics. Aerosol dispenser 21 is placed into the receptacle 6 of the inhalation device 1 of the present invention. As described in conjunction with FIG. 1, the cap (or fixator) 3 is placed over the aerosol dispenser 21 so as to draw aerosol dispenser 21 downwardly into receptacle 6. The aerosol nozzle 22 of aerosol dispenser 21 goes into, abutment with the bevelled edges 8 of forward area 7. When this abutment occurs and when the fixator 3 causes the nozzle 22 to become compressed, the aerosol is dispensed from the dispenser 21 and into the forward area 7 of receptacle 6.
When the diaphragm is in the condition, illustrated in FIG. 5, the forward portion 14a of pin 14 causes a blockage of the atomizer 9. As such, when gas is dispensed from dispenser 21, such gas will reside in the forward area 7 of the receptacle 6. Upon an inhalation the pin 14 will move, as illustrated in FIG. 6, with the deformation of the diaphragm 13. This causes the pin 14 to move beyond the atomizer 9 and, thus, allows the gas to be expelled, in atomizer fashion, through atomizer nozzle 9. When such atomizing occurs, the aerosol medication, along with carbureted air, is received by the user through nozzle 2.
A perforated plug 15 is shown as installed at the bottom of activator 5. This perforated plug 15 prevents external contact with diaphragm 13 and prevents the diaphragm from separating from the body 1a.
As illustrated in FIGS. 1-6, the present invention acts as an automatic inhalation activated medication spray device that, by sucking on the nozzle 2, activates the aerosol pressurized medication canister for the purpose of delivering a dose of its contents to the lungs of the user. The present invention allows asthmatics to treat themselves with a disposable device that ideally times the spray for the beginning of the inhaled breath. It can be seen that this device has only one moving part, the diaphragm/pin assembly 13. This device has no batteries, excessive moving parts, or power requirements.
The present invention carburetes atmospheric air with the medication spray so as to permit a full breath through the device to the user. The amount of air carbureted with the dispensing of the medication is a matter of design choice. The only restriction to the requirement for venting is that less than a free flow of air be transmitted by the vents to the user.
The aerosol canister 21 is a measured dose canister. This is of a standard configuration and is manufactured by a wide variety of pharmaceutical companies. In contrast to standard aerosols, a continuous spray is not dispensed. Rather, a short spray results from releasing a fixed dose of medicine. The dispenser 21 will not dispense again until the nozzle pin is released and depressed again. By atomizing, and dispensing into nozzle 2 at the beginning of a breath, all of the medicine is carried to the lungs at the beginning of the inhalation, rather than dispersed in the mouth, throat, or spray device. As such, a proper dose of medication is actually received by the patient. There is no need to have a "make-up" dose. Furthermore, the present invention prevents overdosage or improper administration. The aerosol canister 21 may also be a continuous spray canister.
Since asthmatics may have coordination problems, especially during attack, the present invention solves that problem by allowing the dosage to be dispensed by mere inhalation. There is no need for manual manipulation nor need for accurate dispensing. In addition, there is no difficulty in timing the breath spray so that the spray is received during the beginning of the inhalation. As such, the present invention achieves a number of advantages that are not found in the prior art dispensing devices.
An alternative embodiment of the present invention is illustrated in FIG. 7. Specifically, FIG. 7 is a schematic illustration showing the arrangement of the inhalator device 1 as connected to a respirator and transmitted to a patient. It can be seen in FIG. 7 that first tube 30 is a tube that extends to a respirator. This respirator is fastened to the receptacle 31 of inhalation device 1. Air from respirator 30 is properly vented to the patient at the end of the second tube 32 by way of the vents in the receptacle 31. The second tube 32 delivers air and medication directly to the patient by virtue of the interaction with the inhalation device 1. When a burst of oxygen is transmitted through first tube 30, this creates a pressure increase in the nozzle 2 of inhalation device 1. When this pressure increase occurs, the medication is dispensed outwardly to tube 32. Medication is then transported directly to the patient's lungs by this configuration. As a result, this alternative embodiment allows for the dispensing of medication by way of the forced pressure through the venting of the receptacle 31. It can be seen that medication dispensing occurs when a pressure increase occurs through the venting area 31. If necessary the diaphragm can be modified to flexably respond to pressure increases in the nozzle instead of, or in addition, to pressure decreases.
Since the embodiment of FIG. 7 dispenses medication quite frequently, it is important that the device of FIG. 7 have a timing apparatus 40 attached to the inhalation device 1. As a result, the timing apparatus 40 will only permit the dispensing of the aerosol medication at properly preset time intervals.
FIG. 8 shows the arrangement of the timing apparatus 40 as utilized in conjunction with the body 1a. It can be seen that timing apparatus 40 is fitted to the exterior surface 41 of body 1a. Such attachment can be accomplished by threading, gluing, or other sealing techniques. Timing device 40 includes an internal clock (not shown) and an abutment member 42. The clock contained within timing mechanism 40 is of conventional configuration. What is important with the use of the timing mechanism 40 is that the clock within the mechanism be interactive with the abutment member 42. This configuration can be in the nature of a solenoid arrangement, or other mechanical configuration. In essence, during periods of non-dispensing, the abutment member 42 will abut the end 43 of pin 44. This present abutment arrangement will prevent movement of the pin despite any deformation of diaphragm 45. As such, pin 44 will serve to block any medication from passing into atomizer 46. Until the abutment member 42 is removed from the end 43 of pin 44, no medication is dispensed.
When the present interval occurs, the abutment member 42 will be drawn into timing mechanism 40. In other words, the abutment member 42 is retracted. Once the abutment member 42 is retracted, the diaphragm 45 is free to deform as needed. When deformation occurs, the pin 44 is drawn downwardly thereby freeing the atomizer for the dispensing of medication into nozzle 2.
As stated previously, the timing mechanism 40 is particularly important when dispensing medication to a patient on a respirator. The timing mechanism 40 may also be useful when dispensing medication to other patients who have the ability to utilize the inhalation device 1 on their own. The dispensing of medication may only be necessary during certain time periods. As such, the timing mechanism 40 can be utilized so as to prevent the patient from getting an overdose. Since the timing mechanism 40 may be more expensive than the inhalation device 1, it may be most expedient to cause the timing mechanism 40 to threadedly engage the walls 41 of body 1a. As such, the timing mechanism 40 may be interchangeable between various inhalation devices 1.
The inhalation device 1 may be utilized in conjunction with breathing tubes, of the type illustrated in FIG. 7, in a variety of ways. One example is that the inhalator device 1 may be installed in the tubes such that the nozzle of the inhalation device fits into one leg of a Y-joint in the tube. In this manner, the air forced through the tube will inhale fresh atmospheric air through the inhalation device 1 so as to carry medication into the tube. The inhalation device may also be installed in line in the tube such that the air that is forced through the respirator enters through the vents of the inhalation device and outwardly through the nozzle of the inhalation device. When the air that is forced into the patient increases the pressure across the interface of the diaphragm, this causes the dispenser to dispense the medicator directly into the patient.
The present invention, in its plurality of embodiments, accomplishes the purposes of delivering the aerosol medication to the patient at the beginning of the inhalation cycle. Additionally, the inhalation device of the present invention can be simply manufactured, simply used, and easily disposed of. As a result, there is little need for additional sterilization, or other manipulative procedures required for the reuse of the present invention. Since the aerosol medications are readily available, the present invention is easily adapted to presently available medications. As such, the present invention achieves a number of advantages that are not found in the prior art.
The foregoing disclosure and description of the invention is illustrative and explanatory thereof, and various changes in the method steps, as well as in the details on the illustrated apparatus, may be made within the scope of the appended claims without departing from the true spirit of the invention. The present invention should be limited only by the following claims and their legal equivalents. | A disposable device for dispensing an aerosol spray medicament to the lungs of a patient from a stanardized aerosol dispenser activated automatically by the inhaling of the user. The device has only one moving part, and no power requirements. The device may be used alone or within a respirator, by asthmatics, pulmonary cancer patients, and others. The device comprises a body having an outwardly extending nozzle, a receptacle formed within the body for receiving the dispenser, and an activator positioned within the body being mechanically interactive with the inhalation by the patient. Vents are formed in the body for carbureting air into the nozzle. A fixator is provided for detachably affixing the dispenser in position within the receptacle. Specifically, the fixator is a cap that is threadedly connected to the body and has an interior area suitable for accommodating the dispenser. The activator comprises a diaphragm positioned within the body. The diaphragm has an elastic quality suitable for being deformable upon a reduction or increase of air pressure within the nozzle. The activator further includes a pin that is fixedly positioned to the diaphragm and extends upwardly transverse to the plane of the diaphragm. The pin acts as a valve between the dispenser and the nozzle. An atomizer is provided between the receptacle and the nozzle for transmitting fluid into the nozzle. A timer may be attached to the device to provide periodic doses when used with an automatic respirator. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS AND CLAIM TO PRIORITY
The present application claims the benefit of U.S. provisional patent application Ser. No. 60/290,342, filed May 14, 2001, the disclosure of which is incorporated by reference.
FIELD OF THE INVENTION
The present invention is directed to a method and apparatus for buffering a flow of stacks of objects, and more specifically, toward a method and apparatus for receiving a first number of stacks of discrete planar objects, such as frozen hamburger patties, from a stacking machine and presenting a second number of those stacks to a packing machine, especially when the first and second numbers are unequal.
BACKGROUND OF THE INVENTION
Frozen hamburgers, chicken patties, sausage patties, and other disk-like food products typically are prepared by a manufacturer on one piece of equipment and then fed into a freezer. After leaving the freezer, they are screened by a metal detector, which detects contaminated patties, and then conveyed to a stacker. The stacker forms the patties into one or more stacks, and the finished stacks are then placed in cases. Because the stacks formed by some stackers can vary in height, and because the number of stacks formed simultaneously by a stacker may be greater than the number of stacks that will fit in a row in a case, the finished stacks are often removed from the stacker and loaded into cases by hand. This manual loading step is labor-intensive, and, due to the presence of a human element, highly variable.
The problem of forming uniform stacks of patties is addressed by the novel stacking machine disclosed in the co-pending application entitled “Method and Apparatus for Stacking Discrete Planar Objects” filed concurrently herewith and assigned to the assignee hereof. The disclosure of that application is hereby incorporated by reference. However, as with many prior art devices, the subject stacker simultaneously forms more stacks than will fit in one row of a typical case. For example, in a preferred embodiment, the subject stacker receives four rows of frozen patties from a conveyor belt and simultaneously forms four stacks of patties. Cases of patties, however, can often accommodate only three stacks of patties per row, or possibly five stacks or more.
This problem could be addressed by adjusting the stacking machine to form only three stacks of patties at a time, but the reduction from four rows to three rows represents a twenty-five percent decrease in efficiency. Human packers can also address this problem by packing stacks one at a time and positioning each stack as required in a given case. However, as mentioned above, it would be desirable to fully automate the stacking and packing processes to provide greater consistency and to reduce costs.
In addition, not all cases are packed in the same manner. Some cases may hold only two rows of patties, for example, and it would be useful to have a machine that could be rapidly adjusted to convert four incoming rows of stacks into two outgoing stacks, depending on the product being packaged, or even to accommodate cases that alternate between two stacks per row and three stacks per row. Ideally, the change would be software controlled or require no more than the push of button to make. And, while reducing the number of rows is the general problem faced by the industry, under some circumstances it may be desirable to present more stacks to a packing machine than are provided at one time by a stacker—for example, if the stacker forms four rows of stacks at a time and a certain case requires six stacks in a row. Finally, the machine should be able to function under conditions where the number of incoming rows is equal to the number of outgoing rows and to do so in an efficient manner.
SUMMARY OF THE INVENTION
These and other difficulties are addressed by the present invention which comprises a novel buffering device that receives a first plurality of stacks of objects from a stacking machine and presents a second number of stacks to a packing machine for removal, where the second number may be greater than, less than, or equal to the first number. The invention includes a plurality of trays or similar receptacles sized and shaped to accommodate the stacked objects, which receptacles are mounted on carriers that can be moved between a first location where the stacks are received from a loading device and a second location where the stacks are removed by an unloading device.
In a preferred embodiment, the invention comprises a carousel around which a belt rotates continuously in a path having two generally parallel linear sections connected by curved portions. Each carrier is attached to the belt by a clamp which engages the belt in a jaw-like manner on opposites sides thereof. The clamp is attached tightly enough to cause the receptacle to move with the belt when the path of the carrier is unobstructed, but loosely enough that the belt will slide through the clamp when the path of the carrier is blocked. In this manner, the position of the carriers can be controlled somewhat independently of the positions of the other carriers without the need to provide separate controllers for the clamps on each carrier.
The movement of the receptacles is controlled so that a first number of receptacles is always available when needed to receive a first number of incoming stacks at a first location. The receptacles are then released to a second location from which the stacks are removed in groups of a second number. When the second number is less than the first number, the stacks must be removed at a rate greater than the rate at which the stacks of patties arrive at the carousel, and full carriers are buffered at a location between the first and second locations. When the second number of carriers is greater than the first number, the full carriers are accumulated at the second location until a second number of carriers is present. When the first and second numbers are the same, the carries merely move around the carousel in equally sized groups. While such a buffer can be incorporated into a stacking or packing machine, in the preferred embodiment, it comprises a stand-alone device that is connected between a stacker and a packer, thus allowing greater flexibility for use with different types stacking and packing machines.
In a preferred embodiment, the device further includes sensors for detecting the presence of carriers at different points around the carousel. A proximity sensor mounted near the path of the carriers detects the carriers as they pass. The sensors are operably connected to stops that block the passage of carriers when the stops are in an extended or in a blocking position. Because the carriers are somewhat loosely connected to the drive belt, the drive belt continues to move through the clamp when a carrier is blocked. Other carriers being moved by the belt engage the stopped carrier, and are likewise stopped. When the stop is moved to a releasing position, the carriers that were blocked begin again to move with the belt. A controller connected to the stops controls them so that so that carriers are released from the first stop in groups of a first number and released from the second stop in groups of a second number, where the first number can be greater than, less than or equal to the second number. Alternately, additional sensors can be used to determine whether the carriers are full or empty. When additional sensors are used, the controller releases only full carriers from the first location, and releases only empty carriers from the second location. Thus, with either embodiment, empty carriers are stopped at the first location and filled with stacks of frozen hamburger patties. When the carriers are full, the controller releases the stop to allow the filled group of carriers to pass and the next empty carrier is stopped. The full carriers travel around the carousel until they reach the second stop, which moves into the blocking position to keep the full carriers from passing. The full carriers remain at this location until stacks are removed by a stack transfer mechanism, and empty carriers are then released to travel back to the first location.
In the preferred embodiment, the number of carriers is related to the maximum number of incoming or outgoing rows of patties in a certain way to minimize the number of carriers needed, and this reduces the amount of space occupied by the machine. Applicant has found, for example, that a buffer for use between a stacking machine that produces four rows of patties and a packaging machine that requires three rows of patties as input, needs eleven carriers. By limiting the number of carriers, the width of the buffer can be kept small and the resulting buffer need not be much greater than the width of the stacking machine.
It is therefore a principal object of the invention to provide an apparatus for receiving a first number of stacks of objects at an input location and presenting a second number of stacks of objects at an output location.
It is another object of the invention to provide a method of buffering the flow of stacks of objects between a stacking machine and a packing machine.
It is a further object of the invention to provide an apparatus for matching the output rate of a first machine to the input rate of a second machine.
It is still another object of the invention to provide a carousel having a plurality of selectively positionable receptacles for receiving a plurality of stacks from a first machine and presenting a plurality of stacks to a second machine.
It is still a further object of the present invention to provide a free-standing stack transfer device that receives a first number of stacks of objects at a first location and presents a second, smaller number of stacks of objects at a second location.
It is yet another object of the present invention to provide a free-standing stack transfer device that receives a first number of stacks of objects at a first location and presents a second, larger number of stacks of objects at a second location.
It is yet a further object of the present invention to provide a buffer device that can be configured to accommodate different numbers of incoming stacks and differing numbers of outgoing stacks.
In furtherance of these objects, a method for buffering a flow of stacks of objects from a first location presenting a first number of stacks to a second location adapted to receive a second number of stacks is provided that includes the steps of providing a frame between the first location and the second location which frame has a first position and a second position. A plurality of carriers each adapted to hold a single stack is associated with the frame and a first number of carriers are moved to the first position. The first number of stacks are transferred from the first location to the first number of carriers at the first position, and then the first number of filled carriers at the first position are moved toward the second position. Whenever at least a second number of filled carriers are present at the second location, the stacks from the second number of filled carriers at the second position are removed to the second location. Lastly, empty carriers are returned from the second position toward the first position.
Another aspect of the invention comprises a system for buffering a flow of stacks between a first location and a second location that includes a frame having a first position with an exit end proximate the first location and a second position with an exit end proximate the second location and a drive. A plurality of carriers is supported by the frame and connected to the drive. The device further includes a first stop at the first position exit end, a second stop at the second position exit end, and a controller for actuating the first stop to allow carriers to pass the first location exit end in groups of a first number and for actuating the second stop to allow carriers to pass the second location exit end in groups of a second number.
A further aspect of the invention involves a method for receiving a first number of stacks of discrete objects from a stacking machine and presenting a second number of the received stacks for removal by a stack transfer machine. The method requires a frame having a periphery, a first location on the periphery, and a second location on the periphery, and a drive on the frame. A plurality of carriers adapted to hold a single stack are mounted on the frame and connected to the drive. A first sensor is provided for counting the number of carriers passing a first point and a second sensor is provided for counting the number of carriers passing a second point. A first stop is provided near the first point for preventing empty carriers from passing the first stop, and one stack is received in each of the first number of carriers at the first location. The first number of carriers are released from the first stop, but stopped at a second location by a second stop near the second point that prevents carriers from passing the second location. A second number of stacks is removed from the first number of carriers at the second location, and the second number of carriers are released by the second stop and moved toward the first location.
Yet another aspect of the invention comprises a buffer including a support frame, a platform having a periphery mounted on the support frame, and a guide extending around the periphery. A drive belt is mounted adjacent the platform along the periphery, and a drive is operatively coupled to the drive belt. A plurality of carriers is supported by the platform, each including a first member engaging the guide and a second member engaging the drive belt such that movement of the drive belt moves the carriers about the periphery of the platform. A first sensor is mounted at a first location for counting the number of carriers passing the first location, and at least one stop is provided that can be shifted between a first position in a path of travel of the carriers around the platform and a second position outside the path of travel of the carriers around the platform. A controller operatively coupled to the first sensor controls the position of the at least one stop.
A further aspect of the invention comprises a carrier having a trolley adapted to support a tray for holding stacks of objects. The trolley has a body with a first side and a second side and includes a first wall portion having an end and a second wall portion extending from the end of the first wall portion at an obtuse angle. An axle extends from the first side of the second wall portion and a wheel is rotatably supported by the second wall portion axle. A clamp is mounted on the first side of the first wall portion.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other objects of the invention will become apparent from a reading and understanding of the following detailed description of the invention together with the following drawings of which:
FIG. 1 is a perspective view of a carousel buffer device having a plurality of trays supported on carriers according to the present invention.
FIG. 2 is an assembly drawing of a portion of the buffer device of FIG. 1 with the carriers and trays removed.
FIG. 3 is a side elevational view of one of the carriers shown in FIG. 1 .
FIG. 4 is a rear elevational view of the carrier of FIG. 3 .
FIG. 5 is a side elevational view of the buffer of FIG. 1 .
FIG. 6 is a side elevational view of the buffer of FIG. 1 showing a stop for preventing the movement of the carriers in a non-engaged position.
FIG. 7 is a side elevational view of the buffer and stop of FIG. 6 showing the stop in an engaged position.
FIGS. 8 a-h are top plan views of the buffer of FIG. 1 showing the locations of full and empty trays around the periphery of the buffer as the buffer is used according to the method of the present invention.
FIG. 9 is a top plan view of the buffer device with the trays removed to show the positions of several sensors.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings, wherein the showings are for purposes of illustrating a preferred embodiment of the invention only, and not for the purpose of limiting same, FIGS. 1 and 2 illustrate a buffer device designated generally by the numeral 10 which includes a frame 12 , a drive 14 and a plurality of carriers 16 supported by the frame 12 . Frame 12 includes vertical support portions 18 adapted to support the frame on a horizontal support surface, a generally planar upper support portion 20 that includes first and second openings 22 , and a motor support 24 mounted beneath upper planar portion 20 .
Drive 14 includes a motor 26 mounted on motor support 24 and operably connected to a drive gear 28 which turns a continuous drive belt 30 about a plurality of flanged wheels, including a first wheel 32 and a second wheel 34 . First and second wheels 32 and 34 each include a center opening 36 having a notch 38 for receiving a splined shaft. Two splined shafts 40 extend from center openings 36 upwardly through first and second openings 22 in the frame upper support 20 .
A bottom plate 42 having first and second openings 44 , as best shown in FIG. 5 , a peripheral edge 46 and a raised rail 48 running around the peripheral edge is mounted on frame upper support 20 with first and second openings 44 aligned with openings 22 in the frame upper support 20 so that splined shafts 40 extend though these openings. Wheels 50 , as best shown in FIG. 2 , are mounted on each of the splined shafts which wheels include center openings 52 shaped to receive shafts 40 and peripheral grooves 54 for receiving and holding a drive belt 56 . The drive belt 56 preferably has a circular cross section and is formed from a flexible, wear-resistant material, such as urethane.
A top plate 58 having first and second openings 60 , a peripheral edge 62 and a raised rail 64 running around the peripheral edge is mounted over bottom plate 42 and spaced apart therefrom by spacers 66 , with openings 58 positioned to receive splined shafts 40 . Bearings 68 are mounted on top plate 56 to rotatably secure the ends of shafts 40 . Thus, motor 26 turns drive gear 28 and causes drive belt 30 to move about first wheel 32 and second wheel 34 , which in turn causes splined shafts 40 and wheels 50 mounted thereon to rotate and drive belt 56 about a continuous path between bottom plate 42 and top plate 58 . Drive belt 56 preferably has a diameter greater than the width of peripheral grooves 54 , so that the belt only contacts the wheels about a small portion, less than 180 degrees, of the belt's circumference.
FIG. 1 illustrates a plurality of carriers 16 mounted on the top and bottom plates which carriers comprise trays 70 supported by trolleys 72 as best shown in FIGS. 2-4 . Each tray 70 includes a bottom wall 74 having a centrally located slot 76 with a slot edge 78 , a rear wall 80 and sidewalls 82 . The trays 70 are preferably mounted on the trolleys 72 in a manner that allows for easy removal thereof, so that appropriately sized trays 70 can be used for the objects being processed. Each trolley 72 , shown in more detail in FIGS. 3 and 4 , includes a body portion 86 having a lower portion 88 with a lower end 90 and an upper portion 92 angled with respect to the lower portion 88 . A wall 94 projects from body lower portion 88 in the same direction as the angle of the upper portion, and includes a small wall 96 projecting from its end in the direction of angled upper portion 92 . A boss 98 is mounted on upper portion 92 and supports a shaft 100 on which a wheel 102 having a V-shaped peripheral notch 104 is rotatably mounted and held in place by a retainer 106 . A wheel support 107 is connected to wall 94 , and small wall 96 supports two shafts 108 on which first and second guide wheels 110 are mounted for rotation about axes parallel to lower portion 88 of body portion 86 . Projections 112 extending from the lower side of wall 94 support two additional guide wheels 114 , which guide wheels are mounted for rotation about axes normal to body lower portion 88 . Guide wheels 115 are also mounted on the bottom side of wall 94 , with axes parallel to body portion 88 and between guide wheels 114 and body portion 88 .
A clamp 116 is mounted on body lower portion 88 between guide wheels 110 and 110 notched wheel 102 , and includes an upper clamp member 118 pivotably supported on lower body portion 88 by a shaft 120 , and a lower clamp member 122 pivotably supported on a shaft 124 extending between lower body portion 88 and small wall 96 . Both the upper and lower clamp members are coated with, or preferably formed from, a low-friction, wear resistant material, such as UHMW polyurethane. The angular relationship between the upper and lower clamp members, and hence the distance separating the ends of the clamp members, can be adjusted by pivoting the upper clamp member and fixing it in place with fastener 126 .
The mounting of carriers 16 on the upper and lower plates is best shown in FIG. 5 , wherein trays 70 are detachably connected to trolleys 72 , and the trolleys are arranged such that notch 104 of wheel 102 on the angled upper portion 92 of the trolley fits over an edge of raised rail 64 on the periphery of top plate 58 , guide wheels 110 engage the inner edge of raised rail 48 on bottom plate 42 , guide wheels 115 engage the outer edge of raised rail 48 , and guide wheels 114 engage the underside of bottom plate 42 .
The upper and lower members 118 and 122 , respectively, of clamp 116 are attached to drive belt 56 by placing the belt between the members and clamping the upper member in place so that a small force is exerted against the belt by the clamp members. The force must be great enough that friction between the clamp 116 and the belt 56 will keep the trolleys 72 fixed with respect to the belt when the path of the trolleys 72 is clear. The force also must be small enough that the frictional force between the belt 56 and the clamp 116 can be overcome by the drive motor to cause the belt to slip through the clamp when movement of one or more of the trolleys 72 is blocked by a stop.
A first solenoid-actuated stop 128 is mounted on frame 12 with a trolley-engaging portion 130 shiftable between a first, release position, shown in FIG. 6 , below the lower ends 90 of the trolley bottom portions 88 and a second, stop, position, shown in FIG. 7 , where the trolley engaging portion 130 blocks a path of the trolley 72 by forming a stop against which the lower ends 90 of the trolleys impact when the stop 128 is in its stopping position. A second, separately controllable, solenoid-actuated stop 134 is provided on the other side of the buffer device.
The shifting of the stops between stopping and releasing positions is controlled by a controller 136 , operably coupled to sensors 132 and 133 mounted on frame 12 below the tray bottom walls 94 , as best shown in FIGS. 5 and 9 . These sensors are used to count the number of trays passing thereby. The controller 136 monitors the number of trays 70 passing over each of the sensors 132 or 133 , and causes the first stop 128 to shift to its stop position when a predetermined number of trays has passed. For example, when the buffer receives four stacks of patties at a time from a stacker, the trays 70 will be released in groups of four. Similarly, when stacks are removed in groups of three, the controller 136 shifts the second stop 134 into the blocking position and only allows the trays 70 to pass in groups of three. The operation of the stops 128 and 134 is coordinated with the operation of the stacker and stack transfer mechanism so that, in the embodiment described herein, at least four empty trays are always available to receive incoming stacks of patties and that at least three stacks of patties are present at the second stop 134 to be removed by a stack transfer device. An optical sensor 135 is also provided for detecting patties on the trays as they approach the loading position. Since these trays 70 should all be empty, an alarm occurs or the system shuts down when full trays are seen approaching the loading position.
As best shown in FIG. 9 , two additional sensors 144 and 146 are also provided to help ensure that enough trays 70 are present upstream of stop 128 to receive incoming stacks of patties and that the correct number of stacks of patties are available for removal by a stack transfer device. Thus, for example, as sensor 128 is counting the passage of four trays 70 , sensor 144 upstream of sensor 128 is counting the passage of empty trays toward sensor 132 and stop 128 . Controller 136 is preferable coupled to the controller for a transfer device that brings stacks of patties to the buffer device 10 and configured so that stacks of patties will not be transferred to buffer device 10 until sensor 144 has detected the passage of four trays 70 . Thus, in the event that a problem arises that prevents four empty trays from lining up behind stop 128 , the transfer device will not attempt to transfer stacks of patties to the buffer device 10 . This reduces the likelihood that patties will be dropped or otherwise mishandled during processing. In a similar manner, sensor 146 counts trays 70 approaching sensor 133 , and as sensor 133 is counting the release of three empty trays 70 , for example, sensor 146 is counting approaching trays to ensure that at least three full trays are present at stop 134 and that at least three stacks are available for removal. Controller 136 is preferably connected to the controller for the downstream stack transfer device and prevents stacks from being removed from the trays stopped at stop 134 until three stacks are present for removal. The number of stacks arriving at and leaving the buffer device 10 can be varied, and the position of sensors 144 , 146 is adjustable so that these sensors can be placed near the location where the last of a given group of trays 70 will be found when the system is operating properly.
In a second embodiment, sensors 132 and 133 are used both to count the number of trays passing thereby and to detect whether the tray adjacent the sensor is full or empty, based upon whether slot 76 is blocked. The controller 136 monitors the status of the trays 70 passing over each of the sensors, and causes the first stop to shift to its stop position whenever an empty tray is detected and to shift to its release position when a full tray is detected. Similarly, controller shifts the second stop into the blocking position when a full tray is detected by sensor 133 and into the releasing position when actuated in an opposite manner, that is, set to prevent the passage of full trays while allowing empty trays to pass.
In operation, motor 26 drives drive belt 30 , turning first and second wheels 32 , 34 and rotating shafts 40 and wheels 52 mounted thereon. This in turn causes drive belt 56 to move continuously about the periphery of the buffer between plates 42 and 58 . The carrier trolleys 72 are clamped to belt 56 tightly enough that they are pulled about the peripheries of the upper and lower plates by the movement of the belt. The trolleys are guided by the engagement of trolley wheels 102 with upper plate raised rail 64 and the engagement of guide wheels 110 , 112 and 114 with the peripheral portion 46 of lower plate 42 . Stops 128 and 134 are selectively moved into and out of the path of travel of the trolleys and, when positioned in a stopping position, prevent trolleys from moving past the stops. The motor 26 continues to operate at a continuous speed, however, sliding belt 56 through clamps 116 even when all trolleys are prevented from moving by the positions of the stops. The urethane from which belt 56 is formed is sufficiently wear resistant that it provides reliable operation even after many hours of continuous use. And, as the relative positions of clamp upper member 118 and lower member 122 are adjustable, the clamps can be repositioned in the event that the diameter of belt 56 decreases slightly after a long period of use to maintain the proper pressure on the belt.
The operation of the subject system will now be described with particular reference to FIGS. 8 a-h which shows the system set up for use with a patty stacker that forms four stacks of patties simultaneously which patties must be packed in boxes that are three patties wide. Thus the buffer will receive stacks of patties four at a time from a first direction, shown by arrows 138 in FIG. 8A , on a first side of the buffer and present them for removal three stacks at a time on a second side of the buffer where they are removed in a the direction of arrows 140 in FIG. 8 C.
FIG. 8A shows four trays 70 a , 70 b , 70 c and 70 d on a first side of buffer 10 which trays have just received four stacks 142 of hamburger patties from a transfer mechanism (not shown). Controller 136 causes stop 128 to move between blocking and releasing positions in order to release carriers in groups of four at predetermined intervals. After four stacks of patties are received in trays 70 a - 70 d , stop 128 shifts to its release position and allows these carriers to pass. The fifth carrier, 70 e , which is empty, and the carriers behind it, are stopped by stop 128 for a predetermined period of time, a period long enough for theses carriers to receive four more stacks of patties from the stacking machine.
As shown in FIG. 8B , additional carriers 70 f and 70 g impact against stopped carrier 70 e and are held in this position as belt 56 slips through clamps 116 on each trolley. Carriers 70 e-g will remain in this position for a predetermined amount of time. Meanwhile, carriers 70 a-d have been carried around buffer 10 by belt 56 toward a second stop 134 that blocks the path of the trays, and tray 70 a impacts against the second stop. Trays 70 b-d impact against stopped tray 70 a and are also brought to a stop with drive belt 56 sliding freely through clamps 116 on each of the stopped trays.
As shown in FIG. 8C , a second transfer device, not shown, removes three stacks of patties from carriers 70 a , 70 b and 70 c in the direction of arrows 140 , and the first transfer device places four additional stacks of patties on carriers 70 e , 70 f , 70 g and 70 h on the first side of the buffer. After a predetermined time, carriers 70 a-c will be empty, and therefore the controller cause these three trays to be released, while the next tray (the last full tray) is stopped. Full carriers 70 e , 70 f , 70 g and 70 h are released by first stop 128 in FIG. 8 C and moved around the buffer until they impact full carrier 70 d held up at second stop 134 resulting in the positioning of trays shown in FIG. 8 D.
FIG. 8E shows that three stacks of patties have been removed from carriers 70 d , 70 e and 70 f and that additional stacks of patties have been placed on carriers 70 i , 70 j , 70 k and 70 a . Four full carriers are released by stop 128 and three empty carriers are released by stop 134 as described above resulting in the arrangement of carriers shown in FIG. 8 f . As shown in FIG. 8G , three additional stacks of patties are removed from trays 70 g , 70 h and 70 i and these now-empty carriers are also released. Full carriers 70 j , 70 k and 70 a remain stopped at stop 134 . Three additional stacks of patties will be removed from carriers 70 a , 70 k and 70 j as shown in FIG. 8H while an additional four stacks are added to trays 70 c , 70 d , 70 e and 70 f at the first side of the buffer, and from there the process continues repeatedly as described above.
The above invention has been described above in terms of a preferred embodiment. However, obvious changes and additions to the invention will become apparent to those skilled in the relevant arts upon a reading of the foregoing disclosure. For example, while the trolleys are described as being connected to a urethane belt in a manner that allows the belt to slide through the trolleys when the motion of a trolley is blocked, a plurality of separately controllable clamps could be used on each carrier to independently control whether a given carrier is connected to a drive belt. Additional sensors could also be added to provide additional information on the position and status of carriers as they travel around the buffer. And, while the buffer has been described in terms of reducing a flow of four incoming stacks of patties to three outgoing stacks of patties, the number of incoming patties could be changed, the number of outgoing patty stacks could be greater than the number of incoming stacks or the incoming and outgoing stacks could be equal in number without departing from the scope of this invention. It is intended that all such obvious changes and additions be included within the scope of this invention to the extent that they are defined by the several claims appended hereto. | A buffer device for buffering a flow of stacks of discrete objects between a stacking machine and a packaging machine is disclosed which buffer includes a plurality of individual trays mounted on carriers which carriers are mounted on a frame and driven about the periphery of the frame by a drive. A first number of stacks of objects is placed on a first number of carriers on a first side of the frame and a second number of stacks are removed from a second number of carriers on a second side of the frame where the first number can be greater than, less than or equal to the first number. The carriers clamp onto a continuously moving drive belt in a manner that allow the drive belt to slip through the carrier clamps when motion of the carriers is obstructed. A method of using the buffer device is also disclosed. | 1 |
BACKGROUND OF THE INVENTION
This invention relates to localized radiation heating and more particularly to localized heating in microwave appliances.
In microwave heating, it can be desirable to provide localized surface heating to achieve such effects as browning and crisping. While the typical microwave oven is a suitable energy source for uniform cooking, it is not satisfactory for selective heating effects, such as browning and crisping. In fact, the typical microwave arrangement produces the cooking in which the external surface of the cooked material, particularly if desired to be crispy, tends to be soggy and unappetizing in appearance.
One attempt to provide suitable browning and crisping of microwave cooked foods has been by the selective use of virtually transparent, thin metallized aluminum coatings. Such material can produce heat and provide the desired crisping. The difficulty with this thickness of metal is that it can produce arcing and defeat the microwave operation.
Another attempt to provide the desired heating effect has been by the suggested use of carbon black coatings. These do not produce arcing but are generally found to be unsatisfactory because they produce a run-away heating effect.
Accordingly, it is an object of the invention to facilitate the selective radiation heating of objects, particularly food. A related object is to improve the taste and texture of microwave heated foods. Another object is to maintain the wholesomeness and nutritional value of food.
A further object of the invention is to overcome the disadvantages experienced in the use of thin metallic coatings in attempting to supply a supplemental heating effect in microwave cooking.
Still another object of the invention is to overcome the disadvantages that have been experienced in obtaining localized heating effects. A related object is to overcome the difficulties that have prevented carbon black coatings from being used for localized heating.
SUMMARY OF THE INVENTION
In accomplishing the foregoing and related objects, the invention provides a medium for selected conversion of radiation to heat in which a fluid carrier is used to disperse conductive and semiconductive substances. The conductive substances desirably are flakes, powder, needles, fiber and fluff, for example, of a metal such as aluminum and the semiconductive substances are particles, for example, of carbon.
The medium is used as a coating or to provide a print pattern of a radiation heating susceptor of conductive and semiconductive substances. It is speculated that the semiconductive substances provide a bridging effect with respect to the metallic substances so that the metallic substances are able to provide a desired controlled localized heating effect without arcing. At the same time, the combination of the semiconductor materials with the metallic substances avoids the runaway heating effect that can occur with homogeneous materials such as carbon black particles.
The medium desirably, includes an antioxidant, a solvent to control viscosity, a fluid carrier which a resin in solution by a primary solvent, and a diluent. The resin is selected from the class consisting of polysulphones, polyethersulphones, polyolefins, epoxies, phenolics, polystyrenes, phenoxies, halocarbons, acrylics and vinyls.
The fluid carrier can include a dispersant solution formed by a solvent or solvent blend and a wetting agent for the substances being dispersed.
A microwave susceptor coating package in accordance with the invention includes a substrate and a susceptor coating on the substrate. The susceptor coating is a combination of semiconductor particles and metallic particles. The ratio of metal to semiconductor is in the range from about 5-30:1, with about 13:1 preferred. The semiconductor can be carbon black. The metal may be flaked or powdered and is selected from the class of nickel, iron, zinc, copper or aluminum.
The microwave susceptor coating is formed from metallic particles accompanied by a substance for reducing the arc effect of the metallic particles. The steps of forming the coating include providing a resin solution, providing a dispersant solution, combining the solutions and dispersing particles into the combined solutions or dispersing the particles in the dispersion solution and combining that mixture with the resin solution.
DESCRIPTION OF THE DRAWINGS
Other aspects of the invention will become apparent after considering an illustrative embodiment taken in conjunction with the drawings in which:
FIG. 1 is a perspective view of a microwavable food package which has been adapted in accordance with the invention;
FIG. 2 is a perspective view of the package of FIG. 1 which is adapted for localized microwave heating;
FIG. 3 is a perspective view showing the invention in use in a microwave oven.
FIG. 4 is a perspective view of the microwave susceptor constriction used in the prior art.
DETAILED DESCRIPTION
With reference to the drawings, a package for microwave cooking is shown in FIG. 1. The package (1) includes a food product (2) within its interior and a removable cover (3) that is removable along a set of incised lines (4). As illustrated in FIG. 1, once the incision is broken, the cover (3) can be elevated to various positions. Three positions are shown in FIG. 1, a preliminary position where the flap has been elevated to the outer side wall (5) of the package, a second position shows the flap being removed from the outer edge and the third position shows the flap extended downwardly.
In FIG. 2 the flap has been folded over the base (6) exposing a "susceptor" coating (7) which provides localized heating in accordance with the invention. The term "susceptor" is commonly used to designate a coating that provides localized heating by absorbing electromagnetic radiation and converting it to thermal energy.
The package of FIG. 2 is insertable into a microwave oven (FIG. 3) with the food item (2) that is to be crispened placed upon the susceptor coating (7).
The susceptor coating shown in FIGS. 2 and 3 provides microwave crisping and browning without the disadvantages that accompanied the prior art.
The susceptor coating of the invention is formed by a combination of metallic powder or flake, carbon and a resin binder. The heating strength of the susceptor coating is controlled by the coat weight (mass), geometry, resin properties (i.e. glass transition temperature) as well as the pigment particle size, choice of metal, pigment to binder ratio and the metal to carbon black ratio.
In use, the susceptor coating may be applied to a film substrate including but not limited to polyester, polyimide, polyetherimide, nylon, cellophane, polyethersulphone or polyvinylidene chloride which is laminated to paperboard. The susceptor coating may also be applied to the package or cooking container, such as a tray. This is used as a cooking surface for the item to be crispened and browned.
The invention provides a microwave susceptor which is not limited to the tight deposition tolerances that are required in metallized susceptors. In addition the coating of the laminate can be printed in various shapes and sizes, be thermoformable and transferable from a release surface.
Conventional metal susceptor coatings do not heat without arcing and can only be used once; carbon black susceptor coatings can burn because of run-away heating.
Variability of heating strength can be controlled by formula modification and pattern. The prior art of metallized aluminum coatings did not provide for variability in heating. Various sizes and shapes of susceptor patterns can be printed with the invention. This provides an advantage over the prior art in which sizes and shapes must be controlled by masking before metallizing or etching after metallizing. The invention is reusable and can be printed on permanent cookware or reusable trays.
The prior art is illustrated by the laminate of FIG. 4. In this laminate (24), a 1/2 mil (0.013 mm) layer or film of olyethylene terephthalate is used as the carrier (20). Upon this is deposited a 15-20 angstroms thickness of vacuum-metallized aluminum (21) that provides a surface resistivity varying between 20 and 50 ohms per square. Overlying the aluminum layer is an adhesive (22) such as ethylene vinyl acetate and an overlying cellulosic layer (23). When exposed to microwave radiation this susceptor heats up but soon shuts off like a fuse. During the heating cycle this susceptor is prone to arcing.
The invention provides a combination of carbon and metallic particles such as nickel, iron, copper, zinc or aluminum. The particles are 1-19 microns in size. The metal/carbon ratio is on the order of 13/1. By using a mixture of metal and carbon arcing is eliminated. It is believed that 15-70 nm particles of carbon provide a semiconductive bridge which maintains metal particle spacings and avoids arcing. Another result is a reusable susceptor. The relationship between the carbon and the metal particles is about 1 to about 5-30 parts by weight. An appropriate ratio is about 1 to 13. As the amount of metal is increased, there is a drop in heating ability. Too much carbon limits utility due to arcing or burning and is avoided.
The coating mass affects the amount of heating. As an example, for one formula, a coating thickness of 19 microns is needed to achieve 260° C. and a thickness of 13 microns is needed to achieve 165° C. Thermoplastic resins are desired for the binder to keep the pigments from overheating. This is related to the glass transition temperature T g . As the T g is reached the binder expands so that at some point the pigment to pigment contact will be lost thereby preventing further heating until the binder cools down and contracts making the pigment particles contiguous again. For polyethersulphone (T g =229° C.) the temperature plateau is 266° C. as compared with 182° C. for polyamide (T g =101° C.) For low pigment loadings thermoset resins are acceptable.
In one example in accordance with the invention, a microwave susceptor coating was formulated beginning with a resin solution of 45.26 parts by weight and a dispersant solution of 4.83 parts by weight. Lecithin was used as a secondary dispersant, 0.20 parts by weight. To control viscosity, 9.58 parts of solvent, e.g., dimethyl formamide, and 9.58 parts of diluent, i.e., methylethylketone, were added to the resin and dispersant solutions. The resin solution was comprised of a diluent at 40 parts by weight and a primary solvent at 40 parts by weight with polyethersulphone as the resin at 20 parts by weight. The polyethersulphone has a glass transition temperature of 229° C. The dispersant solution was comprised of the diluent at 40 parts by weight, the primary solvent at 40 parts by weight and the dispersing agent, a polyester/polyamide copolymer, at 20 parts by weight.
To this were added 6 to 9 microns aluminum particles at 28.35 parts by weight and 2.16 parts of carbon black which were high surface area aggregates of hollow shell-like particles. A phenolic oxamide antioxidant was used to retard oxidation of the metal. A 19 microns thick dried coating of this formula applied to a polyimide substrate heated a contiguous ceramic plate, without a food heat sink, to 254° C. in 2 minutes with a 700 watt output microwave oven.
A second coating example was formulated in the same manner as the first but the amounts of aluminum and carbon black were changed to give an aluminum to carbon black ratio of 8 to 1. Coatings of 19 microns or 13 microns thickness would burn when exposed to microwaves but a 6 microns thick coating would heat a contiguous ceramic plate to 247° C. in 2 minutes.
In a third example the aluminum to carbon black ratio was the same as in example 1, but the total pigment (aluminum and carbon) to binder ratio was 1:1. A 19 microns thick coating heated the ceramic plate to 241° C.
For example 4 the polyethersulphone and the primary solvent of example 3 were replaced with vinyl chloride-vinyl acetate copolymer and an appropriate primary solvent, such as toluene, respectively. A ceramic plate was heated by a 19 microns thick coating to 177° C. in 2 minutes.
In example 5 the vinyl resin and diluent of example 4 were replaced by polyamide and an alcohol, respectively. The heating test yielded a result of 154° C. for a 19 microns thick coating.
For example 6, a coating similar to that in example 3 was made but aluminum was replaced by copper (1-5 microns). A 19 microns thick coating produced a 172° C. result.
Example 7 is the same as example 6 but copper was replaced by nickel (1-5 microns). The result was 266° C.
In example 8, the resin and solvents of example 7 were replaced by a liquid two part epoxy system. The ratio of diglycidal ether of bisphenol A (epoxy) to polyamide hardener is 100:33-125. Similar results were achieved. | A medium formed by a resin binder with conductive and semiconductive particles that can be coated on a substrate to convert electromagnetic radiation to heat. Conversion efficiency can be controlled by the choice and amount of materials used in the medium, which can be used repeatedly without burn out. | 8 |
FIELD OF THE INVENTION
[0001] The present invention is related to deployment systems and methods for accurately and rapidly deploying vascular occlusion devices at a preselected location within the vascular system of a patient, and more particularly, deployment approaches that utilize a pusher having an expandable gripper which is opened by the action of a collapsible chemical reaction chamber to facilitate rapid deployment of vascular occlusion devices.
BACKGROUND OF THE INVENTION
[0002] The use of catheter delivery systems for positioning and deploying therapeutic devices, such as dilation balloons, stents and embolic coils, in the vasculature of the human body has become a standard procedure for treating endovascular diseases. It has been found that such devices are particularly useful in treating areas where traditional operational procedures are impossible or pose a great risk to the patient, for example in the treatment of aneurysms in intracranial blood vessels. Due to the delicate tissue surrounding intracranial blood vessels, especially for example brain tissue, it is very difficult and often risky to perform surgical procedures to treat such a defect. Advancements in catheter deployment systems have provided an alternative treatment in such cases. Some of the advantages of catheter delivery systems are that they provide methods for treating blood vessels by an approach that has been found to reduce the risk of trauma to the surrounding tissue, and they also allow for treatment of blood vessels that in the past would have been considered inoperable.
[0003] Typically, these procedures involve inserting the distal end of a delivery catheter into the vasculature of a patient and guiding it through the vasculature to a predetermined delivery site. A vascular occlusion device, such as an embolic coil, is attached to the end of a delivery member which pushes the coil through the catheter and out of the distal end of the catheter into the delivery site. Some of the problems that have been associated with these procedures relate to the accuracy of coil placement. For example, the force of the coil exiting the delivery catheter may cause the coil to over shoot the predetermined site or dislodge previously deployed coils. Also, once the coil is pushed out of the distal end of the catheter, the coil cannot be retracted and may migrate to an undesired location. Often, retrieving and repositioning the coil requires a separate procedure and has the potential to expose the patient to additional risk.
[0004] In response to the above mentioned concerns, numerous devices and release mechanisms have been developed in an attempt to provide a deployment system which allows control of the occlusion device after the device has been delivered by the catheter and provides a rapid release or detachment mechanism to release the device once it is in place. One such device is disclosed in Geremia et al. U.S. Pat. No. 5,108,407, which shows a fiber optic cable including a connector device mounted to the end to the optic fiber. An embolic coil is attached to the connector device by a heat releasable adhesive. Laser light is transmitted through the fiber optic cable to increase the temperature of the connector device, which melts the adhesive and releases the embolic coil. One drawback to using this type of system is the potential risk of melted adhesives contaminating the blood stream.
[0005] Another coil deployment system employs a pusher member having an embolic coil attached to the pusher member by a connector fiber which is capable of being broken by heat, as disclosed in Gandhi et al. U.S. Pat. No. 6,478,773. The pusher member of this arrangement includes an electrical resistance heating coil through which the connector fiber is passed. Electrical current is supplied to the heating coil by a power source connected to the heating coil via wires extending through an internal lumen of the pusher. The power source is activated to increase the temperature of the heating coil which breaks the connector fiber. One drawback is that connecting the resistance heating coil to the power source requires running multiple wires through the pusher member. Additionally, the electrical current traveling through the wires may create stray electromagnetic fields that interfere with other surgical and/or monitoring equipment.
[0006] Yet another embolic coil positioning and delivery system is described in Saadat et al. U.S. Pat. No. 5,989,242, which discloses a catheter having a shape memory alloy connector attached to the distal end of the catheter. The connector includes a socket having a pair of spaced-apart fingers which are responsive to a change in temperature. The fingers are bent towards each other and hold a ball which is connected to an end of an embolic coil. The connector absorbs laser light transmitted through an optical cable and transmits the light into heat energy. The heat energy raises the temperature of the connector and opens the fingers, thereby releasing the embolic coil. This delivery system and the other above-identified delivery systems require electronic equipment powered by a power source. If the electronic equipment is defective or the power source fails, for example a battery pack fails, the procedure may be prolonged while the equipment is repaired or replaced. Prolonging the procedure may expose the patient to additional risk. This patent, and all other patents and references identified herein are hereby incorporated herein by reference.
[0007] Therefore, a need remains for a rapid release vascular occlusion deployment system or method that does not rely on electrical equipment or a power supply, is simple to manufacture, flexible and easy to guide through the vasculature of the body, provides better control over the occlusion device, and reduces the possibility of interference with other surgical and/or monitoring equipment.
SUMMARY OF INVENTION
[0008] The present invention embodies deployment systems and methods for accurately and rapidly deploying a vascular occlusion device at a preselected site within the vasculature of a patient. The deployment system may employ an elongated flexible delivery catheter for guiding a deployment unit to the preselected site. The deployment unit includes a pusher which has a gripper located at a distal end portion of the pusher. The gripper has an expandable gripping element, for example a plurality of gripping jaws, for releasably attaching a vascular occlusion device, such as an embolic coil, to the deployment system. The pusher guides the vascular occlusion device through the delivery catheter to the preselected site.
[0009] A collapsible or contractible reaction chamber operatively communicates with the gripper. A first reactant is housed within the collapsible reaction chamber. The delivery system also includes a dispensing unit for dispensing a second reactant into the reaction chamber. When the second reactant is dispensed into the chamber, the first and second reactants react to form a product that has a volume that is less than the volume of the first reactant prior to reacting. The reduction of the volume occupied by the substances inside of the reaction chamber causes the pressure within the reaction chamber to decrease which results in a collapse of the reaction chamber. As the reaction chamber collapses, it pulls the proximal end of the gripping element inward causing the distal end of the gripping element to outwardly expand or open so that the gripping element releases the vascular occlusion device, thereby deploying the vascular occlusion device at the preselected location.
[0010] Other aspects, objects and advantages of the present invention will be understood from the following description according to the preferred embodiments of the present invention, specifically including stated and unstated combinations of the various features which are described herein, relevant information concerning which is shown in the accompanying drawing.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] In describing the preferred embodiments of the present invention, reference will be made to the accompanying drawings, wherein:
[0012] FIG. 1 is an enlarged, partially sectioned view of the vascular occlusion device deployment system of a preferred embodiment of the present invention;
[0013] FIG. 2 is an enlarged partially sectioned view showing the distal end portion of the deployment system of FIG. 1 prior to deployment of the occlusion device;
[0014] FIG. 3 is an enlarged partially sectioned view of the distal end portion of the deployment system of FIG. 1 shown just after deployment of the vascular occlusion device; and
[0015] FIG. 4 is an enlarged partially sectioned view of the distal end portion of the deployment system of FIG. 1 shown after deployment of the vascular occlusion device.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0016] As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention, which may be embodied in various forms. Therefore, specific details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present invention in virtually any appropriate manner.
[0017] FIG. 1 generally illustrates a preferred embodiment of the vascular occlusion device deployment system of the present invention. The deployment system, generally designated at 10 , includes an elongated flexible guiding catheter 12 which is inserted into the vascular system of a patient, such as blood vessel 13 , and used to guide a deployment unit, generally designed 14 , to a preselected site in a manner generally known in the art. The deployment unit 14 includes an elongated flexible pusher or delivery tube 16 having a proximal end portion 18 and a distal end portion 20 .
[0018] As best illustrated in FIG. 2 , a gripper 22 is located at the distal end portion 20 of the pusher 16 . The gripper 22 includes an outwardly expandable gripping element 24 , which is generally illustrated as a plurality of jaws 25 . Typically, the gripping element 24 and the jaws 25 will be not occupy the full circumference of the distal end portion 20 and the jaws 25 may, for example, take the form of two fingers protruding distally. The gripping element 24 releasably engages a protruding portion or headpiece 26 of a vascular occlusion device 28 , such as an embolic coil. As will be discussed in more detail below, when the gripping element 24 expands outwardly or opens, it releases the headpiece 26 of the vascular occlusion device 28 .
[0019] The gripper 22 may be comprised of polymer, such as FEP Teflon, PTFE Teflon, polyvinyl chloride, a polyolefin or a neoprene, or any other suitable polymer, and may be constructed as disclosed in Bennett et al. U.S. Pat. No. 5,609,608, hereby incorporated herein by reference. Alternatively, the gripper 22 may be constructed of any suitable metal, or the gripper could comprise a microtube which has been slit. A suitable microtube may be made of stainless steel or of a nickel-titanium alloy such as Nitinol, or other suitable material. Further, in the illustrated embodiment, the gripper 22 and pusher 16 are shown as a unitary structure. However, it will be understood that the gripper 22 could be a separate unit which is attached to the pusher 16 in any suitable manner, for example by a silicone or cyanoacrylate adhesive.
[0020] As stated above, the occlusion device 28 may be an embolic coil which may take various forms and configurations, and may also be filled with a fibrous material or may be coated with a beneficial substance, such as a biogel to promote clotting. Alternatively, the occlusion device also may be any other occlusion device or approach known in the art such as hydrogels, foams, bioactive coils, braids, cables, and hybrid devices.
[0021] A collapsible or contractible reaction chamber 30 is positioned in the distal end portion 20 of the pusher 16 , preferably within the gripper 22 . The reaction chamber 30 comprises a cavity 31 that houses a first reactant 33 which is preferably a gas or a liquid. The cavity 31 is defined by a proximal wall 32 , a distal wall 34 and inner surface 36 of a sidewall 37 of the cavity 31 . The sidewall 37 is constructed such that it will deform inwardly or collapse in response to forces acting on it that are generated as described herein. In the embodiment where the jaws 25 are relatively narrow, the sidewall 37 can have an area of weakness in general alignment therewith to facilitate movement of the jaws during operation as described herein. The first reactant 33 occupies the defined volume of the cavity 31 . This can be considered to create a pressure within the chamber 30 that is equal to or slightly higher than the external pressure outside of the chamber.
[0022] The proximal wall 32 and distal wall 34 are preferably comprised of an elastic membrane which may be attached to the inner surface 36 of the gripper 22 by an adhesive, such as a cyanoacrylate adhesive, or by any other suitable manner. The elastic membranes may be constructed from materials that do not significantly degrade while in contact with the reactant materials or the product formed therefrom. Typically, these will be an elastic polymer, such as silicone, a polyamide, a nylon, or a polyolefin such as polyethylene. Furthermore, the respective membranes will have different Durometer hardness values. For reasons that will be discussed in more detail below, the proximal wall 32 preferably is made of a lower Durometer polymer which can be easily flexed or bent in response to changes of pressure within the reaction chamber 30 . On the other hand, the distal wall 34 preferably is made from a higher Durometer polymer that resists bending or flexing in response to changes of pressure within the chamber 30 .
[0023] The delivery unit 14 also includes a dispensing unit 38 for dispensing a second reactant 40 into the cavity 31 of the reaction chamber 30 . The illustrated dispensing unit 38 comprises a plunger-activated dispensing tube 42 which extends within the pusher 16 from the proximal end portion 18 to the distal end portion 20 of the pusher 16 . A distal end portion 43 of the dispensing tube 42 extends through the proximal wall 32 of the reaction chamber 30 into the cavity 31 . The proximal wall 32 and dispensing tube 42 may be attached and sealed together by an adhesive, such as a silicone or cyanoacrylate adhesive.
[0024] The second reactant 40 may be dispensed from the dispensing tube 42 into the cavity 31 by activating a plunger 44 (which can be seen in FIG. 1 ) located at a proximal end portion of the dispensing tube 42 . The plunger 44 includes a plunger head 45 which forces the second reactant 40 into the cavity 31 of reaction chamber 30 . Typically, the second reactant 40 , prior to dispensing, is secured within the dispensing tube 42 by a breakable seal 46 . Such seals should be selected to be made of a material that does not significantly degrade while in contact with the reactant materials.
[0025] As illustrated in FIG. 3 , when the first and second reactants 33 , 40 are mixed, they produce a product 48 which occupies a volume that is less than the volume occupied by the first reactant 33 prior to mixing. The reduction of the volume occupied by the material within the cavity 31 of the chamber 30 causes activation of the release action to deploy the occlusion device 28 . Activation in this regard effects a reduction in the spacing between opposing inner surfaces 36 . Such reduction in spacing can be caused by a decrease of the pressure within the cavity when the reduced volume product 48 creates a void that is filled by inward movement of the sidewall. Alternatively, or additionally, the product 48 can have adhesive-like properties to assist in such sidewall inward movement.
[0026] Preferably, the plunger head 45 has a sufficiently tight seal with the dispensing tube 42 to ensure that the cavity 31 is completely sealed and to maintain the pressure within the cavity after the reactants react. In the situation where a pressure difference assists in activation of the release action in response to the product reduced volume, the external pressure outside of the chamber 30 acts on the proximal wall 32 and the portion 37 of the gripper 22 defining the cavity to cause the lower Durometer proximal wall 32 and said portion 37 of the gripper to collapse inward, as illustrated in FIGS. 3 and 4 . The higher Durometer distal wall 34 of the reaction chamber 30 is sufficiently rigid to resist the external pressure and substantially retains its original size and shape. The distal wall 34 can provide a fulcrum or pivot point 50 that assists in opening or expanding the gripping element 24 in an outward direction. In other words, the portion 37 of the gripper 22 which is proximal the distal wall 34 collapses inwardly. The collapsing of the portion 37 causes the gripping element 24 , which is located distal the distal wall 34 , to expand outwardly or open about fulcrum 50 .
[0027] The first and second reactants 33 , 40 can be any reactants that produce a product 48 that occupies a volume less than the first reactant 33 . Preferably, the first and second reactants 33 , 40 are substances in the gaseous phase which react to form a gas, solid or liquid product 48 that occupies a volume which is less than the volume occupied by the first reactant 33 . Alternatively, the first reactant 33 can be a substance in the gaseous phase that reacts with the second reactant 40 (a substance in the gas, solid or liquid phase) to produce a liquid or solid product 48 that has a volume less than the first reactant 33 . It is also contemplated that the first reactant 33 could be a substance in the liquid phase that reacts with the second reactant 40 (a substance in the gas, solid or liquid phase) to produce a solid product 48 that has a volume less than the first reactant.
[0028] In operation, the catheter 12 is inserted into the vasculature system of a patient and positioned at a preselected location within a blood vessel 13 , typically in conjunction with other devices and professional procedures as generally known in the art. The delivery unit 14 is inserted into and advanced through the catheter 12 . Once the desired location is reached, the delivery unit 14 is advanced, and/or the catheter 12 is moved in a retrograde manner, such that the delivery unit moves with respect to and within the catheter until the occlusion device 28 moves out of the distal end of the catheter. During the procedure and before the occlusion device 28 has been deployed, if it is determined that the distal end of the catheter 12 or the occlusion device 28 is not in the correct location, the occlusion device may be retrieved back into the distal end of the catheter by retracting the delivery unit 14 proximally or advancing the catheter distally. Once the occlusion device has been retrieved, the catheter and/or the occlusion device may be repositioned.
[0029] When the occlusion device 28 is in the correct position, the plunger 44 may be activated to break the seal 46 and to dispense the second reactant 40 into the cavity 31 of the reaction chamber 30 so that the first and second reactants 33 , 40 mix within the cavity 31 . Referring to FIG. 3 , the first and second reactants 33 , 40 react to form a product 48 which has a volume less than the volume of the first reactant 33 prior to mixing. As described above, the reduction of the volume of the material within the cavity 31 of chamber 30 typically causes the pressure within the cavity to decrease which in turn causes the proximal wall 32 and/or the sidewall 37 of the gripper defining the cavity to collapse. This collapsing action causes the gripping element 24 to pivot about fulcrum 50 and expand outwardly or open, thereby deploying the occlusive device.
[0030] Referring to FIG. 4 , after the occlusive device has been deployed, the delivery unit 14 can be retracted back into the delivery catheter 12 . If desired, the delivery unit 14 can be completely retracted from the catheter 12 and a new delivery unit having similar features can be advanced through the delivery catheter to deploy additional occlusion devices.
[0031] It will be understood that the embodiments of the present invention which have been described are illustrative of some of the applications of the principles of the present invention. Numerous modifications may be made by those skilled in the art without departing from the true spirit and scope of the invention, including those combinations of features that are individually disclosed or claimed herein. | A vascular occlusion device deployment system for placing an occlusion device at a preselected site within the vasculature of a patient. The deployment system employs a pusher including a gripper located at the distal end of the pusher to releasably retain a vascular occlusion device. The gripper is expanded under the force of a collapsible chemical reaction chamber so that the gripper releases the vascular occlusion device, thereby deploying the vascular occlusion device. | 0 |
RELATED APPLICATIONS
This application is a continuation-in-part of U.S. patent application Ser. No. 12/456,445, entitled “Telescoping Mast,” filed on Jun. 16, 2009.
BACKGROUND
1. Field of the Invention
Aspects of the present invention relate in general to cable storage in a retractable telescoping mast. Aspects include a drive mechanism apparatus capable of efficiently storing cable in an extending and retracting the telescoping mast. Further aspects of the invention include an apparatus that spools cable during the extension and retraction of an antenna mast.
2. Description of the Related Art
Telescoping masts of various types have been used in broadcasting and receiving radio messages in many different environments. Included in such developments are telescoping masts, which can be extended vertically or retracted vertically so that they can be mounted on a vehicle and transported to a desired site.
Telescoping masts are frequently used in mobile applications where a radio frequency antenna, temporary cell phone tower, camera, microwave television broadcast antenna or other payloads need to be placed in a position quickly and efficiently.
A mast can be retractable—wherein the mast can be retracted into a storage position in which the mast is relatively short in its overall height dimension. When fully extended or deployed, the overall height is many times larger than its retracted storage height dimension.
Most telescoping masts take a long time to deploy. For example, a four section steel mast might deploy from a 30 foot nested position to a 90 foot deployed position, in about 15 minutes. The energy requirement to move such a heavy and unwieldy mast is also enormous, resulting in the use of expensive motors in a mast drive mechanism.
Faster deploying units require greater power requirements to move the mast, and suffer from even greater problems. Usually the mast payload contains sensitive equipment, which can be damaged if the extension or retraction of the mast is sudden, or results in a jarring movement.
A payload will have electrical requirements. Typically, in such an environment, masts externally route electrical cable to the payload mounted on top of the mast.
SUMMARY
A telescoping mast has a cabling system designed to cover and store cable within the structure of the mast. The telescoping mast has a hollow mast housing. A telescoping section is nested within the interior of the mast housing. A set of upper pulleys affixed to the upper end of the mast housing, while a set of lower pulleys affixed to the lower end of the telescoping section. A cable is threaded through the first upper pulleys and first lower pulleys such that a first end of the cable is attached to the mast housing and the cable remains taut when the telescoping section is raised or lowered.
The mast is able to efficiently extend and retract multiple telescoping sections without jar and minimal energy.
BRIEF DESCRIPTION OF THE DRAWING
FIGS. 1A-D illustrates an embodiment of a telescoping mast and cabling system deployed in an extended and retracted positions.
FIG. 2 is a diagram of a telescoping mast drive mechanism used to efficiently extend and retract the telescoping mast.
FIG. 3 is a block diagram of a telescoping mast computation unit used to control the drive mechanism.
FIG. 4 is a flow chart of a method to control the extension and retraction of a telescoping mast without jar.
DETAILED DESCRIPTION
One aspect of the present invention includes the understanding that when cable is routed external to the mast, damage to unprotected cable easily occurs due to contact with objects; consequently, embodiments of the present invention route cable (electrical, optical, or any other cable known in the art) internally within the mast. Consequently, embodiments protect cable from external objects and environmental conditions by keeping the cable completely covered and stored within the structure of the mast.
In some embodiments, cable runs from the base of the mast to the payload mounted at the top of the mast. The cable is stored internally within the mast housing by spooling up over a set of pulleys. The pulleys move in relation to the mast height and payout or retract the proper length of cable to match the length of mast extension.
Another aspect of the present invention includes the realization that motors driving a telescoping mast may be supplemented by alternate power sources, and that controlling the motors with a computation unit may be used to eliminate jar in telescoping mast movement, resulting in a “soft landing” at any position.
Additionally, the speed of telescoping masts carrying camera payloads may have additional design considerations. For example, such masts deployed in hostile or combat areas may need to rapidly ascend and descend to avoid enemy fire.
Embodiments of the present invention include an apparatus, method, and computer-readable medium configured to control antenna movement to eliminate jar. Other embodiments of the present invention may include supplemental power sources to assist and reduce the power requirements of an electric motor.
Operation of embodiments of the present invention may be illustrated by example. FIGS. 1A-D depict an example telescoping mast, constructed and operative in accordance with an embodiment of the present invention. Telescoping mast 1000 , as shown in FIG. 1A , is a mast assembly extended with telescoping sections 1200 A-G. For illustrative purposes only, seven telescoping sections 1200 A-G are depicted supporting a payload 1100 . It is understood by those known in the art that in embodiments of the present invention may be utilized with any number of telescoping sections 1200 . An example mast assembly is U.S. Pat. No. 6,046,706, entitled “Antenna Mast and Method of Using Same.” Payload 1100 may be any a radio frequency antenna, temporary cell phone tower antenna, camera, microwave television broadcast antenna or other payload known in the art.
In FIGS. 1A-D , a drive mechanism 2000 is used to power and control the extension and retraction of the mast 1000 .
Similarly, FIG. 1B depicts an external view of telescoping mast 1000 in a retracted (or “nested”) state.
Moving on, we now discuss a cabling system of pulleys within the telescoping mast 1000 . FIGS. 1C-D illustrate a system of pulleys within only a single telescoping section. This example is for illustrative purposes only. It is understood by those known in the art that this concept applies equally to any number of telescoping sections. Furthermore, it is worth noting that multiple cabling systems may be run in parallel to support multiple types of cable. Embodiments may include a separate cabling systems for electrical power, digital or analog video/audio, packetized electronic data, or all of the above.
FIG. 1C illustrates internal features of telescoping mast 1000 in a retracted position. As shown, cable 1300 runs from the base of the mast to the payload 1100 mounted at the top of the mast. The cable is stored internally within the mast housing by spooling up over sets of pulleys, 1400 A-B, 1500 A-B. The relative position of pulleys 1400 A-B and 1500 A-B is shown when the mast is in the nested or retracted position. Pulleys 1500 A-B are attached near the bottom of largest moving telescoping section 1200 B of the mast 1000 . The bottom of the largest moving telescoping section 1200 B is directly driven vertically by a lead screw, which is further discussed below. The pulleys move in relation to the mast height and payout or retract the proper length of cable to match the length of mast extension. The mast housing may also serve to protect the cable from external elements such as rain, dirt, tree limbs, moving objects or other external elements. Pulleys 1400 A-B are attached on the inside and near the top of outer stationary section 1200 A of the mast 1000 . The outer stationary section 1200 A of the mast 1000 may also referred to as the mast housing.
As depicted, cable 1300 is a multi-conductor flexible electrical cable that will move through pulleys 1400 A-B and 1500 A-B as the mast 1000 is extended and retracted. As understood by one of ordinary skill in the art, other embodiments may use electrical, optical, computer-networking, or any other cable known in the art. Connectors 1600 A-B may be attached to either end of the cable 1300 , allowing quick electrical/mechanical disconnect of the payload at the top and the control/monitor equipment at the base of the mast 1000 .
FIG. 1D depicts the position of pulleys 1400 A-B and 1500 A-B when mast 1000 is extended. As can be seen, pulleys 1400 A-B and 1500 A-B are closer together, allowing the stored cable 1300 to pay out for any extended mast height. This system of pulleys 1400 A-B and 1500 A-B, along with their relative attachment points 1600 A-B, keeps the cable 1300 under constant tension whether the mast is fully extended, nested or anywhere in between.
FIG. 2 illustrates an embodiment of a drive mechanism 2000 controlled by a computation unit 3000 , constructed and operative in accordance with an embodiment of the present invention. Drive mechanism 2000 includes a drive shaft 2010 with multiple bearings 2020 A-B, coupled to an electric motor 2040 through gears 2050 A-B. The drive mechanism 2000 further includes a position feedback sensor 2030 , a motor 2040 , and a computation unit 3000 . In some instances, drive mechanism 2000 may include a crank 2100 , to enable manual extension or retraction of the mast 1000 .
The drive shaft 2010 itself may be connected to the internal portions of the telescoping sections 1200 via a lead screw attachment point 2070 . It is understood that any attachment point 2070 known in the art capable of transferring the motion of drive shaft 2010 to telescoping sections 1200 would be sufficient.
Position feedback sensor 2030 may any sensor known in the art configured to communicate the telescoping mast 1000 position to computation unit 3000 . The operation of computation unit 3000 is described below.
Motor 2040 may be any motor known in the art capable of raising or lowering telescoping mast 1000 . For illustrative purposes only, motor 2040 is assumed to be an electric motor. The capacity of electric motor 2040 is determined by the mast size. Larger masts require greater horsepower motors. For example, electric motor 2040 could be a ⅛ horsepower DC permanent magnet motor.
Electric motor 2040 may be further supplemented with power from electrical energy storage unit 2060 and/or spring motor 2080 .
Electrical energy storage unit 2060 may be any electrical energy storage unit known in the art, including, but not limited to an ultra capacitor or battery. Electrical energy storage unit 2060 provides a “power buffer” between the peak demands of mast (during mast raising and lowering) and the average load on the electric motor 2040 . Moreover, electrical energy storage unit 2060 allows telescoping mast 1000 to extend or retract if motor 2040 is inoperable or damaged.
Spring motor 2080 may be any potential energy storage unit known in the art. Spring motor 2080 may assist or replace motor 2040 in extending or retracting mast 1000 . Additionally spring motor 2080 is balanced and designed to match the weight and mass of the mast 1000 and its payload 1100 .
In some embodiments, spring motor 2080 may be a constructed from a stressed constant force spring, such as B-Motor springs. B-Motor springs provide high amounts of torque in a small package. An example of such a spring motor 2080 is a constant torque motor from Spiroflex Division of the Kern-Liebers Ltd., part of the Kern-Liebers Group of Companies, of Schramberg, Germany. These spring motors 2080 provide rotational energy from the torque output drum, or linear motion with the use of a pulley, cable, or webbing. While it is convenient for the design that the spring motor 2080 to have constant torque, other spring motors known in the art, such as torsion bars, may be equally applicable.
Crank 2100 may be any manual crank known in the art to enable manual extension or retraction of telescoping mast 1000 . Crank 2100 allows users to manually extend or retract telescoping mast 1000 when motor 2040 is inoperable. In some instances, energy from crank 2100 may also be stored by spring motor 2080 .
FIG. 3 depicts a computation unit 3000 , constructed and operative in accordance with an embodiment of the present invention. Computation unit 3000 comprises a central processing unit 3100 capable of communicating to electric motor 2040 , and position feedback sensor 2030 . Computation unit 3000 may run an embedded operating system (OS) and include at least one processor or central processing unit (CPU) 3100 . In some alternate embodiments, computation unit 3000 runs a standard non-real-time operating system. Central processing unit 3100 may be any microprocessor or micro-controller as is known in the art.
The software for programming the central processing unit 3100 may be found at a computer-readable storage medium (not shown) or, alternatively, from another location across a communications network. Central processing unit 3100 is connected to computer memory. Computation unit 3000 may be controlled by an operating system that is executed within computer memory.
Storage medium may be a conventional read/write memory such as a magnetic disk drive, floppy disk drive, compact-disk read-only-memory (CD-ROM) drive, digital versatile disk (DVD) drive, flash memory, memory stick, transistor-based memory or other computer-readable memory device as is known in the art for storing and retrieving data.
Turning to the functional elements contained within central processing unit 3100 , central processing unit 3100 comprises mast controller 3200 , data processor 3300 , and application interface 3400 . Mast controller 3200 further comprises position monitor 3202 and drive control unit 3204 . It is well understood by those in the art, that these functional elements may be implemented in hardware, firmware, or as software instructions and data encoded on a computer-readable storage medium.
Data processor 3300 interfaces with storage medium, electric motor 2040 , and position feedback sensor 2030 . The data processor 3300 enables mast controller 3200 to locate data on, read data from, and send data to, these components.
Application interface 3400 enables central processing unit 3100 to take some action with respect to a separate software application or entity. For example, application interface 3400 may take the form of a windowing or other user interface, as is commonly known in the art.
The function of position monitor 3202 and drive control unit 3204 are described below.
FIG. 4 is a flow chart of a process 4000 to control the extension and retraction of a telescoping mast without jar, coming in a smooth stop (also known as a “soft landing”) in accordance with an embodiment of the present invention. Soft landings help prevent damage to sensitive payloads 1100 , such as cameras, radio-frequency antennas, microwave television broadcast antennas, cellular phone towers, satellite communication dishes, and the like.
Initially, a user sets the desired position of the telescoping mast 1000 . In some embodiments, telescoping mast 1000 may simply be set to extended or retracted positions. In other embodiments, variable telescoping mast 1000 heights may be specified, where the height is set in between the fully extended or fully retracted positions. In either case, the application interface 3400 reads the set position at block 4002 .
Position monitor 3202 reads the actual (or “current”) mast position, block 4004 . In some embodiments, the extension and retraction of mast 1000 is measured by resistance or voltage fed into an analog-to-digital converter. In such embodiments, mast position may be indicated as a voltage on a variable resistor or potentiometer.
When the mast set position is greater than the actual position, as determined by mast controller 3200 , flow continues at decision block 4008 . Otherwise, flow continues at decision block 4014 .
At decision block 4008 , if the actual mast position is close to the set position, drive control unit 3204 decelerates electric motor upward, block 4010 . If the actual mast position is not close to the set position, drive control unit 3204 accelerates electric motor upward, block 4012 .
At block 4022 , the mast controller 3200 compensates for movement by spring motor 2080 .
When the mast set position is less than the actual position, as determined by mast controller 3200 at decision block 4014 , flow continues at decision block 4016 .
At decision block 4016 , if the actual mast position is close to the set position, drive control unit 3204 decelerates electric motor downward, block 4018 . If the actual mast position is not close to the set position, drive control unit 3204 accelerates electric motor downward, block 4020 .
When the mast set position not less than the actual position, as determined by mast controller 3200 at decision block 4014 , drive control unit 3204 disables the motor 2040 , stopping mast movement at block 4024 .
The previous description of the embodiments is provided to enable any person skilled in the art to practice the invention. The various modifications to these embodiments will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other embodiments without the use of inventive faculty. Thus, the present invention is not intended to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein. | A telescoping mast with a cabling system configured to cover and store cable within the structure of the mast and able to efficiently extend and retract multiple telescoping sections without jar and minimal energy. The telescoping mast has a hollow mast housing. A telescoping section is nested within the interior of the mast housing. A set of upper pulleys affixed to the upper end of the mast housing, while a set of lower pulleys affixed to the lower end of the telescoping section. A cable is threaded through the first upper pulleys and first lower pulleys such that a first end of the cable is attached to the mast housing and the cable remains taut when the telescoping section is raised or lowered. | 4 |
INTRODUCTION
This application relates to flare pipes for the burning of excess or waste gases. More particularly the present invention relates to a flare pipe tower structure and the method of construction of such a tower. Additionally and significantly the present invention relates to the use of telescopic members for construction of the flare pipe tower.
BACKGROUND OF THE INVENTION
Flare pipes that burn at their tip end waste gases or other inflammables are required to be of greater height than in previous years in order to minimize any adverse effect of the heat and radiation upon personnel and equipment. Flare pipes of 300 feet or more are frequently required and their construction has posed serious problems for those in the industry.
Typically, flare pipe towers in the past have been tubular, welded one piece constructed section by section by being built from the ground or platform upwardly as each section is placed on top of the previous section. As is readily understood because of the height requirement for flare pipe towers, the crane required to raise the top most sections must itself be well over 300 feet making the construction very difficult if not impossible because of the expensive requirements of such a high crane and particularly when such a flare tower is to be installed in less than easily accessible places such as offshore. The flare pipe tower as understood must be usable either offshore on a platform or deck or on land where the flare pipe tower is resting on a base or other support.
OBJECTS OF THE INVENTION
Accordingly it is an object of the present invention to provide a flare pipe tower that is easily constructed and safely usable in a wide variety of locations and weather conditions.
A further object of the present invention is the telescopic construction of the flare pipe tower utilizing tower section assemblies that include a pipe section secured within the tower section.
A further object of the present invention is to introduce the tower section assemblies into a bottom section resting on a bore for telescoping upwardly to form the tower and the included flare pipe.
It is a still further object of the present invention to provide the transportation system including a dolly travelling on a track to transport additional tower section assemblies into the bottom section resting on a base that could be the platform or ground.
A further object of the present invention is the provision of a flare pipe section support means that permits vertical sliding movement but limits lateral motion of the foare pipe section.
A further object of the present invention is to raise the flare pipe section in alignment with previously installed flare pipe sections and relative to the tower section to align the flare pipe for welding.
Another object of the present invention is to provide a lower section that is placed within the bottom section and connected to as well as supporting the weight of the previously installed tower sections and which lower section is tapered downwardly to contact the deck or ground within a significantly smaller area than the cross-sectional area of the top of the lower tower section or the bottom of the tower sections in order to provide additional support for the flare pipe tower beyond that of the bottom section.
A still further object of the present invention is to provide a transportation system including a dolly and track arrangement for transporting tower section assemblies to and into the V-shaped opening in the bottom section.
These and other objects will be apparent from the study of the present invention as outlined in the following specification and claims.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of a portion of the sequence for the erection of the flare pipe tower.
FIG. 2 is a view similar to that of FIG. 1 showing the completion of the sequence for the erection of the flare pipe tower.
FIG. 3 is a perspective view of the bottom section showing the V-shaped opening or door on at least one side and the guide tracks upon which the dolly moves into and out of position beneath the bottom section.
FIG. 4 is a perspective view similar to that of FIG. 3 but further along in the sequence for construction in that it discloses the top tower or mast section T1 positioned on the dolly for travel along the guide tracks through the V-shaped door opening in the bottom section.
FIG. 5 is a view similar to FIG. 4 and further along in the sequence showing the dolly travelling through the V-shaped door of the bottom section and in position within the bottom section ready for telescopic raising
FIG. 6 is a perspective view similar to FIG. 5 and further along in the sequence wherein the mast section T1 is telescopically raised, the dolly has moved outwardly to receive new mast section T2.
FIG. 7 is a perspective view similar to that of FIG. 6 but illustrating intermediate mast section T2 installed within bottom section and connected to top mast section T1 and the dolly having been removed from the mast section T2 along the guide tracks to receive the next intermediate mast section T3.
FIG. 8 is a side view partly broken away of the sequence of installation wherein mast or tower section assemblies T1 and T2 have been telescopically raised and next intermediate mast section T3 on the dolly is poised for admittance to the bottom section.
FIG. 9 is a side view similar to that of FIG. 8 and also partly broken away illustrating the receipt of mast or tower section T3 on the dolly for subsequent connection.
FIG. 10 is a cross-sectional view taken along lines 10--10 of FIG. 8 and partly broken away illustrating the rollers on the bottom section for assisting the telescopic movement of the mast section assemblies.
FIG. 11 is a fragmentary side view taken along lines 11--11 of FIG. 10 and illustrating the guide roller arrangement and its contact with the mast section assembly.
FIG. 12 is a fragmentary cross-sectional view taken along lines 12--12 of FIG. 10 and illustrating the section guides.
FIG. 13 is a magnified fragmentary cross-sectional view of the area shown and identified as FIG. 13 in FIG. 8
FIG. 14 is a side view taken along lines 14--14 of FIG. 13.
FIG. 15 is a cross-sectional view partly broken away taken along lines 15--15 of FIG. 8.
FIG. 16 is a fragmentary cross-sectional view taken along lines 16--16 of FIG. 8.
FIG. 17 is a side view of FIG. 16.
FIG. 18 is a plan view of the dolly.
FIG. 18A is a side view of the dolly of FIG. 18.
FIG. 19 is a side elevational view partly broken away of the dolly shown in position of FIG. 5 carrying the mast or tower section T1 and also illustrating the limit stop and the tie down for the dolly.
FIG. 20 is an enlarged fragmentary cross-sectional view in accordance with the circle shown as FIG. 20 in FIG. 19.
FIG. 21 is an enlarged fragmentary cross-sectional view of the detail identified as FIG. 21 in FIG. 19 and also illustrating the tie down latch in the unlatched position.
FIG. 22 is a plan view in cross-section partly broken away of FIG. 21.
FIG. 23 is a fragmentary view of the tracking bar on the track beam upon which the flanged wheels with roller bearings move for transporting the dolly.
FIG. 24 is a view similar to that of FIG. 21 but showing the latch assembly in a latched position.
FIG. 25 is a side view of FIG. 24 and partly broken away.
FIG. 26 is an elevational view partly broken away of the flare pipe section and flare pipe support illustrating the gap between the flare pipe prior to upward adjustment by the hydraulic jacks and also illustrating in the flare pipe on the left the dowel pin engaging the guide tabs while on the right the dowel pin has not yet descended into the opening in the guide tabs.
FIG. 27 is an elevational view partly broken away similar to FIG. 26 in which the hydraulic jacks have been actuated to raise the flare pipe sections sufficiently to close the gap between the pipe sections in order to permit the pipe sections to be welded.
FIG. 28 is a cross-sectional view partly broken away taken along lines 28--28 of FIG. 26.
FIG. 29 is a cross-sectional view partly broken away taken along lines 29--29 of FIG. 26.
FIG. 30 is a perspective view of the erected flare pipe tower.
SUMMARY OF THE INVENTION
A telescopic flare pipe tower supports a flare pipe several hundred feet above the base level and includes a bottom section in contact with the base that may be the ground or the platform or deck offshore. The bottom section has an opening on one side that forms a door or opening. Tower section assemblies that include a tower section and a flare pipe section are transported on a dolly travelling on a track into the center of the bottom section and telescopically raised above the bottom section. Each tower section assembly includes a flare pipe and a securing means that permits relative vertical movement of the flare pipe section relative to the tower section but substantially restricts lateral movement. Upon installation of the second tower section assembly below the superposed previously telescoped tower section assembly the flare pipe section may be raised by a jack positioned on the ground, the deck or other base level to move the flare pipe section up to the superposed flare pipe section for welding.
The method of erecting the telescopic flare pipe tower utilizes the track system with the dolly carrying the tower section assemblies into the bottom section. Each tower section assembly then may be telescopically raised in order to subsequently retrieve the dolly along the guide tracks for use in mounting the next tower section assembly in serial sequence. After the second tower section assembly has been connected to the top most tower section assembly and both tower section assemblies raised to permit the withdrawal of the dolly to set the tower section assemblies down to the ground, deck or platform, the flare pipe section is raised by a hydraulic jack to permit welding of the flare pipe sections to form a flare pipe. After the last tower section assembly has been installed and telescopically raised a lower section is installed below the superposed tower section assemblies for providing vertical support of the tower at a point within an area substantially reduced from the cross-sectional area of the tower.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In FIGS. 1 and 2 there is a schematic showing of the construction of the flare pipe tower as shown in FIGS. 1A through 1H of FIG. 1 and FIGS. 2A through 2E of FIG. 2. The completed flare pipe tower is shown at 30 of FIG. 1H and in FIG. 30. The completed flare pipe 32, is conventional and has an outlet or flare tip at 34 for the gases to be burned in an extended flame as is also conventional.
The flare pipe tower 30 of the present invention includes a bottom section 36 that can be best seen in the perspective views of FIGS. 3 through 7. Bottom section 36 includes four legs 36a, 36b, 36c and 36d that stand above a central location identified as C that may be at the level of base B on the ground if the flare pipe tower is to be assembled onshore at a ground installation or on a deck or platform of an offshore facility. Each leg 36a through 36d includes a longitudinal leg 37a through 37d respectively that extends from the base B forming the corners of the bottom section and are there angled inwardly and upwardly to the top 38 of the bottom section. The top of the bottom section is framed by horizontal braces 39 from which suitable lifting blocks 40 depend reeved with suitable lines 41 to winches 42 on the base level B. The four corners 44a through 44d respectively are provided with rollers 46 secured to the horizontal braces 39 in a suitable manner as shown. The rollers may be made of a suitable hard rubber and are orthogonally positioned relative to each other to assist in the telescopic raising of tower section assemblies through rolling contact therewith as shown in FIG. 1D411.
The bottom section, as readily apparent from the drawings, includes an opening or door 48 formed by angled support members 50. The opening 48 is to be high enough and wide enough to permit the entry of the tower section assemblies 86 as shown in FIGS. 1 and 2 and especially FIGS. 4 through 7 and as will be later described.
One of the features of the present invention is the use of guide tracks 52 which constitute a pair of rails 52a and 52b that are laid on the base B and extend from outside the bottom section 36 to a point beyond the approximate middle of the bottom section at C. The guide tracks are best shown in FIGS. 20, 21 and 23 to be formed from I beams that establish the rails 52a and 52b. Positioned on top of each of the rails is a tracking bar 54 that extends the length of the rail or track 52a and 52b.
Designed to traverse the guide tracks 52 is a dolly 56 having a plurality of flanged wheels 58, as shown particularly in FIGS. 19 and 23. The dolly is formed from a plurality of horizontal beams supporting depending brackets 59 that hold the flanged wheels 58 for rotation in the conventional manner about axis 64. Dolly 56 as it traverses the guide tracks 52 is limited in its travel into the bottom section by a stop that has an abutment surface 67 to contact the foreward edge 68 of the dolly.
As best shown in FIG. 1b and FIG. 4, the top tower or mast section T1 is shown at 70. Subsequent tower sections may be designated T2, T3, T4, etc. The tower or mast section 70 is similar in structure to all subsequent tower sections to be installed and telescoped subsequently as shown in FIGS. 1C through 1H and FIGS. 2A through 2E. The tower or mast section T1 is composed of four upright tower legs 72a through 72d secured together at corners 73 by a plurality of horizontal cross-members.
One of the unique features of the present invention is the inclusion of one or more flare pipe sections 76 within each tower section. The upper flare pipe section in the top most tower or mast section T1 may be referred to as P1. Later added flare pipe sections may be referred to as P2, P3, P4, etc. At the top of the flare pipe P1 is a flare tip 34 positioned at the flare pipe outlet. While several flare pipes and flare pipe sections 76 are shown in the drawing the following description will relate to only a single flare pipe, it being understood that each flare pipe or flare pipe section is constructed in a similar manner.
Another of the unique features of the present invention is the support 80 for the flare pipe sections as best shown in FIG. 4 and FIGS. 28 and 29. Each of the tower or mast sections 70 includes at least one of the supports 80 preferably more than one. As is shown in the drawings, particularly in FIG. 4 there are three such supports that may be identified as 80a, 80b and 80c reading from top to bottom. FIG. 28 is an illustration of the top most support 80a while FIG. 29 depicts the intermediate or lower support 80b. Support 80 is formed with a plate 81 held within the tower section 70 by four horizontal diagonals 82 that extend from plate 81 to the tower legs 72a through 72d.
As best shown in FIGS. 28 and 29 the plate 81 is formed from two halves 81a and 81b coupled together at 83 in a suitable manner by bolts through upturned edges 84.
To accommodate two flare pipes 32, the plates are each formed semicircular cutouts to create with suitable openings 85 that have a diameter large enough to permit the thermal expansion of the completed flare pipes during the passage of the heated gases but loose enough to permit vertical movement of the flare pipe sections when welded or partially welded together to move vertically relative to the plate 81 and therefore relative to the tower section 70. The purpose of each of the supports 80 is to limit the lateral or sidewise movement of the flare pipe 32 but to permit vertical movement for purposes to be disclosed hereinafter.
The unique combination of the flare pipe section P1 with the mast or tower section T1 is referred to as a tower or mast section assembly 86 or in series A1, A2, A3, etc. in that both the flare pipe section and the mast section are included in the one structure.
Each of the tower mast assemblies 86 and therefore each tower section 70 includes at least one platform P upon which workers may stand to perform duties such as welding the flare pipe sections together. In order to gain access to the platforms P a suitable ladder L with surrounding cage is positioned vertically on one side of the tower section.
Referring to the drawing, particularly FIGS. 4, 5, 6 and 7, it will be quite apparent that each tower or mast section assembly 86 is secured to the dolly 56 for transportation through the V-shaped opening or door 48 to be positioned over the center C within the bottom section 36.
The tower section assembly 86-A1 and therefore the tower section 70-T1 is provided with a pair of depending fingers as shown best in FIGS. 16 and 17 as well as FIGS. 20 and 21. These fingers identified as 88,88 are connected at their face by a connector pad 90 and each finger has a bore hole 92 that is mutually aligned for receipt of a pin 94 shown only in FIGS. 13 and 14 for the connection between adjacent superposed tower section assemblies.
Cooperative upstanding flanges 96a and 96b are secured to the top of dolly 56 as best shown in FIGS. 20 and 22. The upstanding flanges are spaced apart sufficiently to receive the pair of fingers 88,88 as shown in FIG. 20. For ease of installation one of the upstanding flanges 96, as shown at 96b, is flared at the top at 96c. When the fingers 88,88 have dropped into place between the flanges 96a and 96b, their downward movement is limited by the top of the dolly 56 at which time the bore hole 92 in the fingers 88,88 coincide with similar bores 98 in the upstanding flanges 96 so that the tower section assembly can be pinned by a suitable pin such as 94 to temporarily hold the tower section assembly 86-A1 to the dolly.
After the tower section assembly 86 with the tower section T1 as shown in FIG. 4 is secured to the dolly 56, the dolly 56 is rolled on the guide tracks 52 so that the tower section assembly 86-A1 with the tower section T1 and flare pipe section P1 passes through the opening 48 until the dolly strikes the limit stop 66. At this point, the tower section assembly will be directly over point C and directly below the open top of the bottom section 38.
To secure both the tower section assembly 86 and the dolly 56 to the base B, a mast section tie down latch 100 pivoting about stationary pin bracket 101 is provided. This tie down latch is shown in the unlatched position FIG. 21 and in the latched position in FIG. 24 with the unlatched position shown in phantom lines. The tie down latch is in the form of an L-shaped latch pivoted about axis 102 so that the bore 92 of the depending fingers 88,88 would coincide with the bore 104 on the other leg of the latch whereby a suitable pin such as 94 would be able to secure the tower section assembly 86 relative to the base B.
It should be noted that the temporary tie down latch assembly 100 is used only when the tower section assembly 86 is positioned on the dolly 56 and the dolly 56 with the tower section assembly mounted thereon is properly positioned within the bottom section 36.
When properly positioned, latched and lifting blocks 40 secured, the pinning of the tower section assembly 86 to the dolly through bores 92 may be released, freeing the tower section assembly to be telescopically raised. The lifting blocks 40 secured in the conventional manner to the bottom of the tower section assembly 86, permit the tower section assembly to be telescopically raised to the position shown in FIG. 1C so that it is sufficiently high enough to permit the next tower section T2 and accompanying flare pipe section P2 in the tower section assembly 86-A2 to follow. As soon as the tower section T1 has been sufficiently raised, tower section assembly 86-A2 travels on the dolly 56 into the position originally taken by tower section assembly 86-A1 where again the limit stops for the dolly 66 are operative.
At this time tower section T1 should be immediately superposed over tower section T2 particularly as shown in FIGS. 15 and 16. At the top of tower section T2, complementary upwardly raised fingers 106a and 106b are positioned each of which have mutually aligned bores 108. Finger 106a is provided with a pin keeper tab 110 to fit a complementary pin in the bore 112 in the pin keeper tab 110 that will align with a similar opening in keeper pin 94 to maintain the pin 94 in position. To facilitate the alignment of the depending fingers 88,88 into the spaced fingers 106a and 106b that extend upwardly, section guides 112 may be provided at each of the four corners as shown in FIG. 12.
Once the tower section assemblies A1 and A2 are pinned in accordance with the pin connections arrangements described in regard to FIGS. 15, 16 and 17 and as shown in FIG. 1C, the tower section assemblies A1 and A2 are raised using the winch 42 and lifting blocks 40 connected to the bottom of the tower section assembly A2. The dolly 56 may then be removed along the guide track 52 from beneath the bottom section 36. The tower section assemblies A1 and A2 are now lowered to contact the base B and assume the position as shown in FIG. 7.
In the position shown in FIG. 7 the flare pipe sections 76-P1 and P2 are not welded together and in fact are spaced slightly from each other to form a gap G between these pipes as shown in FIG. 26. Also as shown in FIG. 26 as well as FIG. 27 a pair of opposed guide tabs 114a and 114b is provided with suitable aligned bores 116. The flare pipe sections P1 and P2 may be aligned by use of a dowel pin 118 that passes through complementary bores 120 on each side of the opening 85 in the plate 81 as shown in FIG. 28. The dowel pin 118 can be dropped into the bore 116 of the guide tabs 114a and 114b as shown in the flare pipe section P2 on the right hand side of FIG. 26. The dowel pin 118 has been previously dropped through the guide tabs 114a and 114b in the flare pipe section P2 on the left hand side of FIG. 26.
In the position as shown in FIG. 26, the flare pipe sections P1 and P2 are aligned but as yet not connected. In order to close the gap G between the pipes, a jack that may be hydraulic or pneumatic is shown in FIG. 26 beneath the flare pipe section P2. Activation of the jack moves the flare pipe section P2, as shown in FIG. 27, up to the point where the flare pipe sections may be welded.
After the weldments are accomplished additional tower section assemblies A3, A4, A5, etc. with included tower sections T3, T4, T5, etc. and flare pipe sections P3, P4 and P5 are serially added to proceed from the showing at FIG. 1D through the completed construction in FIG. 2D and 2E except for the lower section shown in FIGS. 2D and 2E.
In the sequence of construction up to essentially FIG. 2C wherein numerous tower section assemblies have been serially added and the tower sections and pipe sections pinned or welded as required, another feature of the present invention is evident. Particularly as shown in FIG. 3. Following the raising of each of the tower section assemblies 86 a final lower section 124 is added which is different than any of the previous tower section assemblies.
As shown in FIG. 30 the lower section 124 is composed of 4 angled legs 125a, 125b, 125c and 125d that extend downwardly from the top 126 of the lower section that is essentially coextensive and within the four corners of the last tower section to be added but instead of being vertically dependent and in line with previous tower section legs 72a through 72b, the legs 125a through 125d are angled downwardly to meet essentially at a point that would be in the proximity of point C on the ground or on the deck. It is intended that the weight of the tower or tower 30 with each of the tower section assemblies 86 connected together would be supported by the lower section 124 and its approximate contact point C.
As should be manifest the construction as described provides a fifth leg of vertical weight support for the flare pipe tower. In addition to each of the legs 36a through 36d of the bottom section a fifth leg equivalent provided by the converging of the legs 125a through 125d for supporting the weight of the column of tower section assemblies provides additional support not previously attainable in prior art constructions. The legs 36a through 36d of the bottom section 36 provide wind stability against lateral movement or tipping while the principal weight of the tower of the present invention is supported by the generally trapezoidally or conically shaped lower section 124.
It is obviously not necessary that the converging legs 125a through 125d meet at any point such as C or that these legs are continuous and aligned but the closer they do come together the more room there is for worker access beneath the bottom section 36. In any event it is believed that the converging of these legs provides a cross-sectional area of their contact with the base B that is significantly smaller (at least less than 50%-85%) in cross-sectional area than the top 126 of the lower section 124 and particularly the tower section assemblies. While not critical, this convergence is of significant benefit to those beneath the tower.
The riser pipe 128 shown in FIGS. 2D and 2E containing the gases to be burned may be connected to the bottom of the completed flare pipe 32 that may extend below the bottom of the last tower section assembly to be raised or the top 126 of the lower section 124. A saddle (not shown) may be used to hold the riser pipe vertical, if desired, but that construction forms no part of the present invention. | A telescopic flare pipe tower supports a flare pipe several hundred feet above the base level and includes a bottom section in contact with the base that may be the ground or the platform or deck offshore. The bottom section has a door or opening through which tower section assemblies including a tower section and a flare pipe section are transported on a dolly travelling on a track and telescopically raised above the bottom section. Each tower section assembly includes a flare pipe that permits vertical movement relative to the tower section but substantially restricts lateral movement. Upon installation of the second tower section assembly below the superposed previously telescoped tower section assembly the flare pipe section may be raised by a jack positioned on the ground, the deck or other base level to move the flare pipe section up to the superposed flare pipe section for welding.
The method of erecting the telescopic flare pipe tower utilizes the track system with the dolly carrying the tower section assemblies into the bottom section. Each tower section assembly then may be telescopically raised in serial sequence. The flare pipe section is raised by a hydraulic jack to permit welding of the flare pipe sections to form a flare pipe. | 4 |
TECHNICAL FIELD
The invention relates to the transmission of audio signals.
BACKGROUND OF THE INVENTION
The AGC circuit and/or limiter circuit in the transmitter section of a TV broadcasting system artificially raises low levels of audio signals of a broadcast commercial to an allowable maximum level and then transmits the resulting signals over associated transmission media, e.g., antenna, coax cable, fiber, etc. The effect of artificially raising the level of such audio signals may create a result not intended by the producer of the commercial. For example, assume that a television commercial as produced purposely starts with a low-level audio signal, e.g., -20 VU audio signal, then slowly increases the volume of the audio signal over a predetermined period of time, e.g., 10 seconds. However, when the commercial is processed by particular broadcast television equipment for transmission over associated transmission media, the AGC and/or limiter circuits in such equipment artificially increases the -20 VU (low-level) audio signal portion of the commercial to, for example, -5 to 0 VU, thereby diminishing the desired effect intended by the producer of the commercial.
SUMMARY OF THE INVENTION
The relevant art is advanced, in accord with an aspect of the invention, by controlling an audio signal in such a way that the desired effect intended by the producer of the commercial is not diminished. More specifically, such an audio signal is first summed with a stabilization signal having a predetermined frequency to form a composite audio signal in which the stabilization signal has a level that prevents any increase signal level that may be artificially imposed on the composite signal by transmission equipment processing the composited signal. Once the composite signal has been so processed, then the stabilization signal is removed therefrom and the original audio signal is outputted to associated transmission media.
BRIEF DESCRIPTION OF THE DRAWING
In the drawing:
FIG. 1 is a broad block diagram of commercial recording studio in which a principal aspect of the invention may be practiced; and
FIG. 2 is a broad block diagram of commercial broadcast facility in which the principles of the invention may be practiced.
DETAILED DESCRIPTION
It is noted that although the following discusses the claimed invention in the context of television broadcasting, that should not be construed as being a limitation of the claimed invention, since it is apparent that the invention may be practiced in any application where there is need to control the level of an audio signal that will be processed by AGC or limiter circuits. (It is noted that the terms AGC and limiter circuits as used herein include any type of circuit and/or device which increases the level of a signal to a level prescribed by a predetermined requirement, e.g., a transmission requirement.) Moreover, the following discussion uses the term "stabilization signal" which is defined herein as being a signal that remains at a constant level, for example, a level of 0 VU, in which the frequency of the stablization signal is selected for a given application. In certain applications, the constant level will be an allowable level set by the respective application.
With that in mind, the following first discusses the way in which the stabilization signal is generated and added to a commercial broadcast soundtrack and then discusses the processing of the resulting signal at a broadcast facility. Specifically, recording studio 100 shown in FIG. 1 includes audio playback device 5 for reproducing in a conventional manner the original sound track of a commercial broadcast that is recorded on storage media 6, e.g., magnetic tape. Audio playback device 5 includes control 7 for adjusting the level of the audio signal that device 5 outputs to VU meter 10. The level of the audio signal that device 5 outputs is thus monitored by VU meter 10 to ensure that the level does not exceed, for example, 0 VU. The output of VU meter 10 is then presented to input 11 of audio device 15, which may be, for example, a conventional audio mixer.
In accord with an aspect of the invention, a stabilization signal is combined with the audio signal in a conventional manner to prevent the level of the latter signal from being artificially increased when it is being processed by particular broadcasting equipment. Specifically, stabilization signal 32 is generated by a conventional sine wave generator 30 which includes volume control 31 for adjusting the level of stabilization signal 32. In accord with an aspect of the invention, the level of the stabilization is monitored by VU device 35 and adjusted using volume control 31 to ensure that the level of the stabilization signal does not exceed a predetermined transmission level, e.g., a level of 0 VU. (For the purpose of the present application and not by way of limitation, as noted above, the frequency of stabilization signal 32 in accord with the present illustrative application of the invention is set to, for example, 18 kHz. The reason for selecting that frequency will become apparent below.)
Continuing, VU device 35 then presents the stabilization signal to input 12 of audio device 15. Audio device 15, in a conventional manner, sums the input signals appearing at inputs 11 and 12 to produce a single, output signal (i.e., a composite signal), which is presented to path 16. Similarly, audio device 15 includes volume control 17 for ensuring that the level of the "mixed" audio signal that is outputted to path 16 does not exceed 0 VU as monitored by VU device 20. The mixed audio signal is then presented to recording device 25 where it is recorded onto storage media 26, which may be, for example, video tape. In an illustrative embodiment of the invention, device 25 may be, for example, a so-called D2 digital video tape recorder. The recording produced by device 25 may then be presented to a television broadcast facility, e.g., a television station, for commercial broadcast.
A broad block diagram of such a facility is shown in FIG. 2 and includes, inter alia, playback device 205 which outputs to path 206 for presentation to audio/video processing equipment 210 the information that has been prerecorded on storage media 26. Processing equipment 210 includes conventional television broadcasting equipment such as AGC and limiter circuits, amplifiers, audio compressors, signal modulators, signal combiners, etc. Such equipment processes the signal that is received via path 206 such that the AGC circuit of equipment 210 is stabilized (controlled) by the stabilization signal to prevent the AGC circuit (not shown) from raising the level of the original audio signal stored on storage media 6 (FIG. 1) and which forms part of the composite signal recorded on media 26.
Equipment 210, more particularly, processes the signal that it receives via path 206 in accord with a plurality of well-known transmission requirements. One such requirement, in this case broadcast television, band-limits the audio signal that is outputted to path 211 to a frequency range of 50 Hz to 15 kHz. Since the frequency of the stabilization signal is not within the required band-limited audio range, it is removed (filtered out) by equipment 210 leaving, in accord with the aspect of the invention, an audio signal that is virtually identical to the original audio signal 8 (FIG. 1). Thus, in accord with an aspect of the invention, stabilization signal 32 prevents equipment 210 from artificially increasing the commercial audio signal.
Following the processing of the commercial broadcast signals that it receives via path 206, equipment 210 outputs a processed version of signal 8 to path 211 for presentation to conventional transmitter equipment 215. Equipment 215, in turn, presents the commercial broadcast signal to an associated transmission media, e.g., a transmitting antenna for over-the-air transmission. (It is noted that for the sake of clarity and conciseness, the processing of video signals has been omitted from the Figs. and the foregoing).
The foregoing is merely illustrative of the principles of the invention. Those skilled in the art will be able to devise numerous arrangements, which, although not explicitly shown or described herein, nevertheless embody those principles that are within the spirit and scope of the invention. For example, although the invention has been discussed in the context of commercial broadcast television, it may also be practiced in any application where there is need to control the level of an audio signal that will be processed by AGC or limiter circuits, as mentioned above. For example, such a need may be found in such applications as commercial radio, (AM and/or FM), cellular and/or wired telephone transmission, film industry, satellite, fiber optic transmission, infrared as well as high-definition television. | To prevent particular transmission equipment from artificially increasing low level audio signals to a predetermined allowable level, such signals are first summed with a stabilization signal having a predetermined frequency to form a composite audio signal. Moreover, the stabilization signal has a level that prevents any increase in signal level that may be artificially imposed on the composite signal during the processing of the composite signal by the transmission equipment. Once the composite signal has been so processed, then the stabilization signal is removed therefrom and the original audio signal is outputted to associated transmission media. | 7 |
FIELD OF THE INVENTION
The present invention relates generally to flush toilet facilities, and more specifically to a cover installable on or integrated with the seat, which cover fits over the flush handle on the toilet tank when the seat is raised. The result is that the seat must be lowered before the handle may be used to flush the toilet.
BACKGROUND OF THE INVENTION
Since the development of the hinged toilet seat, there has been an ongoing problem between men and women who use the same toilets. The hinged seat was developed for sanitary reasons, to allow men, who naturally urinate while standing, to do so without inadvertently wetting the seat. After finishing, the tendency is to leave the seat in the upright position. Women, who always use toilets with the seat in the lowered position, have seen this as inconsiderate or worse on the part of men, and men are constantly reminded by women to return the seat to the lowered position after using a toilet. Even so, it can be difficult for a male to remember to do so under all circumstances.
The need arises for a device to force persons using a toilet to return the seat to the lowered position without fail, after using the toilet. The device should preclude the use of another function of the toilet (i.e., operation of the flush handle) while the seat is raised. By installing such a device on the seat, or forming it integrally with the seat, the seat must be lowered in order to allow access to the flush handle.
DESCRIPTION OF THE PRIOR ART
U.S. Pat. No. 4,195,372 issued to Minnie Farina on Apr. 1, 1980 discloses an Automatic Seat Return Spring For Relatively Pivoted Toilet Seat And Cover Assemblies. The device comprises a leaf spring fitted around the standard toilet seat and lid hinge pin or rod, and serves to arcuately bias the lid and seat apart from one another to automatically urge the seat to a lowered position. A person wishing to use the toilet with the seat raised, must continually hold the seat in the raised position while performing other tasks (urination, cleaning of the bowl, etc.), which is cumbersome, to say the least. While the spring may be removed as desired, the removal operation is at least equally cumbersome, as the device is intended to remain in place. The present invention allows the seat to function normally, so it may be placed in and rest in the raised position where it will remain until again being lowered manually.
U.S. Pat. No. 4,477,933 issued to Franklin J. Leckie on Oct. 23, 1984 discloses a Toilet Seat Closure comprising a coil spring securable to the lip of the water tank of a toilet, and disposed to the front thereof to apply resilient pressure to a lid which is raised against it. As the seat is installed between the lid and the rim, the result will be to automatically urge the seat downward along with the lid. Again, the seat (and lid) must be continually held in the upright or raised position when the toilet is used by standing males or for cleaning, which operation is cumbersome. As in the Farina device discussed above, the Leckie spring may be removed by lifting the toilet tank cover and removing the spring from the upper edge of the tank, but that operation is also cumbersome whenever lifting of the lid and seat are desired.
U.S. Pat. No. 4,512,046 issued to Rita C. Riggle on Apr. 23, 1985 discloses a Toilet Guard adapted to be secured to a toilet lid, and at least partially covering the flush handle when the lid is raised. The device is intended to ensure that both the underlying seat and the lid are closed before the toilet may be flushed, in order to prevent access to the toilet bowl by small children. The present invention is not intended to relate to operation of the lid or to secure thereto, but rather to operation of the seat, and is adapted to secure thereto or to be formed as a unit therewith. As the seat is normally spaced somewhat away from the front surface of the toilet tank and the handle extending therefrom when the seat is raised, due to the presence of the lid between the seat and tank, the present invention in at least some embodiments allows for this spacing by means of an offset. Such is not disclosed by Riggle, as Riggle does not foresee the installation of her device on other but the lid, which is immediately adjacent the flush handle when the seat is raised.
U.S. Pat. No. 4,519,105 issued to James R. Blanck on May 28, 1985 discloses an Apparatus For Closing Toilet Seat Cover comprising a spring mounted arm having one end secured to the front surface of the toilet tank. The arm has a handle guard on the opposite end, and is normally in an outwardly disposed position from the handle. However, when the seat is raised against the arm, the arm is pushed back to cover the flush handle with the cover. When the cover is pulled forward to access the flush handle, the arm applies pressure to the top of the lid, causing it to fall forward to a closed position. The device does not secure to the seat and does not permit the seat to be lowered while the lid remains raised as in the present invention.
U.S. Pat. No. 4,551,866 issued to Walter G. Hibbs on Nov. 12, 1985 discloses an Automatic Toilet Seat Lowering Apparatus essentially comprising a spring loaded hydraulic damper secured to the back of the bowl rim and having a linkage communicating with the rear edge of the seat adjacent the hinge. When the seat is raised, the damper spring is compressed, whereupon the viscous damper fluid resists seat closure motion through the linkage and the seat is automatically lowered slowly due to gravity. No flush handle cover, or securing of a single component fixed device directly to a toilet seat, is disclosed.
U.S. Pat. No. 4,839,928 issued to Timothy C. Probasco on Jun. 20, 1989 discloses a Device For Lowering Toilet Seats comprising a device attachable to the flush handle and having a wedge extending therefrom. When the handle is pivotally operated, the wedge is driven between the lid and seat, urging the seat forward whereupon it will fall to a lowered position against the rim of the toilet bowl. The present device does not secure to the handle, but merely guards the handle against activation until the seat is lowered.
U.S. Pat. No. 5,056,165 issued to Reginald E. Wescott, Sr. on Oct. 15, 1991 discloses a Commode Flush And Seat Lift Apparatus providing for the lifting of a toilet seat upon actuation of the flushing mechanism by pedal means. The relatively complex mechanical linkage, lack of a guard or cover over the flush handle, and means raising the seat upon flush activation, rather than lowering the seat as is the intent of the present invention, render the Wescott, Sr. device completely different from the present invention.
Finally, British Patent No. 2,256,206 to Gary D. Denham et al. and published on Dec. 2, 1992 discloses a Lavatory Seat Cover having a latch extending from the forward edge thereof, with a catch normally gripping the underlying toilet seat. When the lid or cover is raised normally, the seat is also raised due to the catch raising the seat with the lid. The latch must be pulled outward from its spring biased position to release the catch and allow the lid to be raised while keeping the seat in a lowered position. The device has no relation to the toilet flush handle, and operation of the flush handle is completely independent of any action of the toilet seat or to the lowering thereof before flushing.
In addition to the above comments, it is noted that several of the above devices (Leckie, Riggle, Blanck) include either a protrusion extending from the back of the toilet tank (Leckie, Blanck) or from the back of the lid (Riggle). Many persons wish to rest their backs against the seat while using the toilet, or to lean against the tank while sitting upon the lid during other bathroom activities. The above devices preclude such postures due to their extending from the tank or back of the lid, unlike the present invention. The present invention is advantageous as in at least one embodiment it is secured to the underside of the seat, which area is not rested against at any time. In at least one other embodiment the present flush handle cover is formed as a unit with the seat and extends to one (or both) side(s) thereof, where it produces no discomfort at any time to a user of the toilet.
None of the above noted patents, taken either singly or in combination, are seen to disclose the specific arrangement of concepts disclosed by the present invention.
SUMMARY OF THE INVENTION
By the present invention, an improved guard or cover for a toilet flush handle is disclosed.
Accordingly, one of the objects of the present invention is to provide an improved toilet flush handle guard which in at least one embodiment is adapted to be secured to the underside of a toilet seat, to fit within the gap between the seat and the rim of the bowl, and to cover the flush handle of the toilet when the seat is raised, thereby requiring the seat to be lowered before the flush handle may be activated.
Another of the objects of the present invention is to provide an improved toilet flush handle guard which in at least one embodiment includes an offset providing for immediately adjacent positioning of the handle cover portion over the handle, allowing for the thickness of the seat and lid.
Yet another of the objects of the present invention is to provide an improved toilet flush handle guard which in at least one embodiment includes at least an upper and/or side handle cover extension, thereby more effectively blocking access to the flush handle before the seat is lowered.
Still another of the objects of the present invention is to provide an improved toilet flush handle guard which in at least one embodiment, may be formed in combination with a toilet seat as a single unit.
A final object of the present invention is to provide an improved toilet flush handle guard for the purposes described which is inexpensive, dependable and fully effective in accomplishing its intended purpose.
With these and other objects in view which will more readily appear as the nature of the invention is better understood, the invention consists in the novel combination and arrangement of parts hereinafter more fully described, illustrated and claimed with reference being made to the attached drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a conventional toilet, seat, and lid assembly having a toilet tank with flush handle extending from the upper front surface thereof, showing the flush handle cover of the present invention covering the flush handle with the seat in the raised position.
FIG. 2A is a front or bottom perspective view of one embodiment of the flush handle cover of the present invention, showing its features.
FIG. 2B is a top or rear perspective view of the embodiment of FIG. 2A, showing additional features and the adhesive seat attachment means.
FIG. 3 is a front or bottom perspective view of another embodiment of the present flush handle cover.
FIG. 4 is a front or bottom perspective view of yet another embodiment of the present flush handle cover.
FIG. 5 is a bottom perspective view of a toilet seat having a flush handle cover formed intearally therewith.
FIG. 6 is a bottom perspective view of another embodiment of an integral seat and flush handle cover.
FIG. 7 is a bottom perspective view of yet another embodiment of an integral seat and flush handle cover, showing handle cover extensions symmetrically disposed to both sides.
FIG. 8 is a bottom perspective view of still another embodiment, similar to that of FIG. 7.
Similar reference characters denote corresponding features consistently throughout the several figures of the attached drawings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now particularly to FIG. 1 of the drawings, the present invention will be seen to relate to a handle cover 10 for the flush handle H of a conventional flush toilet T, with the toilet T having a bowl B with an upper rim R therearound, and a hinged seat S and lid L each capable of being selectively lowered over the rim R or raised to rest against the front surface F of a water tank W. The handle cover 10 includes a seat attachment portion 12 and an opposite handle cover portion 14 extending therefrom, with the seat attachment portion 12 comprising a flat, planar element sufficiently thin to fit within the standard gap G provided between the underside U of the seat S and the rim R when the seat S is lowered to rest upon the rim R.
FIGS. 2A and 2B provide more detailed views of the toilet flush handle cover 10 of FIG. 1. FIG. 2A discloses a larger front perspective view (or what might be considered a bottom perspective view, when the cover 10 is secured to a lowered toilet seat S) of the handle cover 10, while FIG. 2B discloses a rear (or top, if secured to a lowered seat S) perspective view. The seat attachment portion 12 and handle cover portion 14 may include an intermediate offset portion 16, which provides for the closer placement of the cover portion to the flush handle H when the seat S is raised. As the seat S and the overlying lid L have some finite thickness, generally on the order of 1.5 to 2 inches total, a device secured to the underside U of the seat S will be spaced accordingly from the front surface F of the toilet tank W when the seat S is raised against the tank W, with the lid L being sandwiched therebetween, as shown in FIG. 1. The result is that a flat, planar component extending straight out from the underside U of the seat S with no offset will be positioned some distance from the handle H, even if it is otherwise secured to the seat to overlie the front of the handle H when the seat S is raised. The offset 16 of the flush handle cover 10 of FIGS. 1 through 2B allows the handle cover portion 14 to be positioned immediately adjacent the handle H when the seat S is raised by compensating for the combined thicknesses of the seat S and lid L; this is generally shown in FIG. 1. With the handle cover portion 14 positioned immediately adjacent to and in front of the handle H when the seat S is raised, the handle H is less accessible, thereby requiring the seat S to be moved forward and downward to a lowered position to access the handle.
Further coverage for a flush handle H may be provided with a first extension 18, which first extension 18 extends rearwardly from the upper edge of the handle cover portion 14 of the handle cover 10 when the seat S is in an upright position as shown in FIG. 1. The first extension 18 overlies the top of the handle H when the seat S is raised, thereby further preventing access of the handle H when the seat S is raised.
As noted above, the handle cover 10 secures to the underside U of a toilet seat S. Further security for the cover 10 may be provided by a fairing 20, which fits partially around and over the generally curved periphery of the seat S. The extension lip of the fairing 20 will be seen to provide further security for the handle cover 10 when it is secured to a seat S. A resilient elastomer or other lining 22 may be provided within the fairing 20, to substantially seal any gap between the fairing 20 and the seat S and provide a substantially smooth, even, and continuous surface across the seat S and the contiguous surface 24 of the fairing 20.
Handle cover 10 may be adhesively secured to the underside U of a toilet seat S my means of an adhesive coating 26 on the attachment surface 28 of the seat attachment portion 12. A removable protective overlay 29 is placed over the adhesive coating 28 before installation of the handle cover 10, and removed to expose the adhesive coating 26 to provide for the adhesive attachment of the handle cover 10 to the underside U of the toilet seat S. Other means (e.g., mechanical/screws, etc.) may be used to secure the handle cover 10 to the underside U of the seat S, as desired. However, the adhesive means provides fewer gaps, spaces, etc. due to the elimination of screw heads and the like, thereby providing for ease of cleanup of the area.
FIG. 3 discloses another embodiment of the present invention, showing a somewhat simplified handle cover 30. The handle cover 30 of FIG. 3 includes a flat, planar seat attachment portion 32, with a similarly flat and planar handle cover portion 34 extending therefrom. The two portions 32 and 34 are mutually coplanar, with no offset provided. In some cases, such a relatively flat and planar handle cover 30 may provide sufficient guarding and/or coverage for some toilet flush handles, depending upon the specific configuration of the toilet and its components. A first extension 36, analogous to the first extension 18 of the handle cover 10 of FIGS. 1 through 2B, is provided to extend over a toilet flush handle H when the seat S to which the handle 30 is secured is in a raised, upright position, thereby further reducing access to a flush handle H positioned behind the handle cover 30. Handle cover 30 may be adhesively secured to the underside U or bottom of a toilet seat S, in the manner discussed above for handle cover 10, or otherwise secured to the underside U of the seat S.
FIG. 4 discloses yet another embodiment of the present invention, comprising a toilet flush handle cover 40. The handle cover 40 of FIG. 4 is similar to the cover 30 of FIG. 3, but includes a curved intermediate portion 46 between the seat attachment portion 42 and the handle cover portion 44. This curved intermediate portion 46 may provide for the more accurate positioning of the handle cover portion 44 over a flush handle H, depending upon the specific seat configuration, handle location, and relationship therebetween for a given toilet T. The handle cover 40 includes a first extension 48 which extends rearwardly from the handle cover portion 44 to overlie a handle H positioned thereunder when the seat S to which the handle cover 40 is attached is raised to an upright position, in the manner of the analogous first extensions of the handle covers 10 and 30 discussed above. However, the handle cover 40 of FIG. 4 also includes a second or side extension 49, which serves to block access to the handle H from the side and essentially provides a box-like enclosure from the front, top, and outboard sides of the flush handle H therein. The lower or underside and inboard side of the handle H are not directly covered by the handle cover extensions 48 and 49, but access from those directions is relatively cumbersome, thus encouraging a person to lower the seat S in order to manipulate the handle H. It will be seen that the second or side extension 49 of the handle cover 40 of FIG. 4 may also be incorporated in any of the other embodiments discussed above, as well as such features as the intermediate curved portion 46. Conversely, the offset 16 of the handle cover 10 of FIGS. 1 through 2B may be incorporated with the handle cover 40 of FIG. 4, if desired.
Each of the above described embodiments of FIGS. 1 through 4 is initially provided separately from the toilet seat S, for attachment thereto to provide the benefits of the present invention. However, further embodiments, in which such flush handle covers are formed integrally with a seat, may also be provided. FIG. 5 discloses a front/bottom perspective view of a toilet seat 50 having a flush handle cover 52 formed integrally therewith and extending therefrom. The flush handle cover 52 of the seat 50 is positioned to overlie a flush handle H extending from the front surface F of a toilet water tank W when the seat 50 is raised to the upright position, thereby blocking access to the handle H until the seat 50 is lowered to expose the handle H. The handle cover 52 may also include a first extension 54 extending therefrom, in the manner of the first extensions of the embodiments of FIGS. 1 through 4 and serving a similar function. It will be seen that the seat 50 may comprise a continuous, toroidally shaped periphery, or alternatively may have an opening 56 at the front thereof (shown in broken lines); the handle cover 52 may be formed equally well with either type of seat, as desired.
A similar embodiment to the one of FIG. 5 is shown in FIG. 6, with a toilet seat 60 having a relatively wide handle cover 62 extending therefrom. In some cases, it may be desirable to provide a relatively large extension flange, for toilet seats 60 exposed to hard use. (e.g., public toilets and/or toilets used by small children, etc.) The relatively wide flanges 64 between the seat portion 66 and the handle cover portion 62 provide greater strength for the handle cover portion 62, and additional coverage for relatively non-standard flush handle positions. Such seats 60 may include a front opening, as in the seat 50 of FIG. 5, if desired.
FIGS. 7 and 8 also include unitary extensions monolithically formed as an integral component of their respective seats. In FIG. 7, front/bottom perspective view of a seat 70 is disclosed, which includes a relatively wide front portion 72 having symmetrical extensions 74 and 76 extending to each side thereof. The leftmost extension 74 serves to cover a flush handle H positioned conventionally to the left front of a typical toilet water tank W, while the right hand extension 76 provides symmetry and an additional means of lifting the seat 70 with either hand.
The seat 80 of FIG. 8 is also shown from a front and bottom perspective view, with the front portion 82 thereof also having a left side 84 and right side 86 extension to each side thereof, generally in the manner of the seat 70 of FIG. 7. It will be noted that the seat 80 of FIG. 8 has a somewhat more conventionally shaped front portion 82, with curvilinear extensions 84 and 86. The extensions 84 and 86 (or 74 and 76) may be formed as desired or required for virtually any toilet and flush handle configuration; the right side extension 86 of the seat 80 of FIG. 8 serves the same purpose as that of the right hand extension 76 of the seat 70 of FIG. 7.
The above embodiments of a toilet flush handle cover provide for the covering of a toilet flush handle H when the toilet seat S (or 50 or 60) is raised to an upright position, in order to require the seat to be lowered for a person to access the flush handle H of the toilet T. The requirement for a person to lower the seat before flushing the toilet, ensures that a subsequent (particularly female) user of the toilet will find the seat considerately lowered for their use. The various features of the above embodiments may be combined in various ways, i.e., the second or side extension 49 disclosed in FIG. 4 may be applied to the embodiments of FIGS. 1 through 3, 5, and 6, if desired. The various cover embodiments discussed above may be formed of a durable plastic material, or even stamped or otherwise formed of metal, particularly in those embodiments lending themselves to construction from a planar sheet of material. Other materials may be used as desired, depending upon the configuration of the handle cover and of the seat to which the cover is to be secured or formed integrally therewith. Accordingly, the above disclosed toilet flush handle cover in its various embodiments provides a relatively inexpensive and durable means if insuring that users of a toilet will place the seat in the lowered position after use without fail, in consideration of subsequent, particularly female, users of the toilet facility.
It is to be understood that the present invention is not limited to the sole embodiments described above, but encompasses any and all embodiments within the scope of the following claims. | A toilet flush handle cover or guard is attachable to the bottom of a toilet seat and provides cover for the flush handle of a conventional toilet when the seat is raised to an upright position. The cover is formed to require a male user of the toilet to lower the seat to access the flush handle and flush the toilet after use, thereby providing considerate positioning of the seat of the toilet in the lowered position for subsequent female users. The flush handle cover may be formed in various configurations in order to provide proper coverage for various flush handles as desired, or alternatively may be formed as a single, integral unit with the toilet seat to extend therefrom. The present handle cover is adapted to remain clear of the upper surface of the seat and of any portion of the lid or tank, thus insuring comfort for a user of the toilet. The handle cover may be formed of a variety of materials, such as relatively thin sheet metal bent or formed to the proper shape, but is preferably formed of plastic and/or of the same materials as the accompanying toilet seat. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation in part of prior application Ser. No. 08/941,463, filed Sep. 30, 1997.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not applicable.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to marine seismology, in which a moving ship generates seismic waves and detects reflections. Still more particularly, the invention relates to the correction of the detected seismic waves for the motion of the ship.
2. Background of the Invention
The field of seismology focuses on the use of artificially generated elastic waves to locate mineral deposits such as hydrocarbons, ores, water, and geothermal reservoirs. Seismology also is used for archaelogical purposes and to obtain geological information for engineering. Exploration seismology provides data that, when used in conjunction with other available geophysical, borehole, and geological data can provide information about the structure and distribution of rock types and their contents.
Most oil companies rely on seismic interpretation for selecting the sites in which to invest in drilling exploratory oil wells. Despite the fact that seismic data is used to map geological structures rather than finding petroleum directly, the gathering of seismic data has become a vital part of selecting the site of an exploratory and development well. Experience has shown that the use of seismic data greatly improves the likelihood of a successful venture.
Seismic data acquisition is routinely performed both on land and at sea. At sea, seismic ships deploy a streamer or cable behind the ship as the ship moves forward. The streamer includes multiple receivers in a configuration generally as shown in FIG. 1. Streamer 110 trails behind ship 100 which moves in the direction of the arrow 101. As shown in FIG. 1, source 112 is also towed behind ship 100. Source 112 and receivers 114 typically deploy below the surface of the ocean 70. Streamer 110 also includes electrical or fiber-optic cabling for interconnecting receivers 114, and the seismic equipment on ship 100. Streamers are usually constructed in sections 25 to 100 meters in length and include groups of up to 35 or more uniformly spaced receivers. The streamers may be several miles long and often a seismic ship trails multiple streamers to increase the amount of seismic data collected. Data is digitized near the receivers 114 and is transmitted to the ship 100 through the cabling at rates of 7 (or more) million bits of data per second. Processing equipment aboard the ship controls the operation of the trailing source and receivers and processes the acquired data.
Seismic techniques estimate the distance between the ocean surface 70 and subsurface structures, such as structure 60 which lies below the ocean floor 63. By estimating the distance to a subsurface structure, the geometry or topography of the structure can be determined. Certain topographical features are indicative of oil and/or gas reservoirs.
To determine the distance to subsurface structure 60, source 112 emits seismic waves 115 which reflect off subsurface structure 60. The reflected waves are sensed by receivers 114. By determining the length of time that the seismic waves 115 took to travel from source 112 to subsurface structure 60 to receivers 114, an estimate of the distance to subsurface structure 60 can be obtained.
The receivers used in marine seismology are commonly referred to as hydrophones, or marine pressure phones, and are usually constructed using a piezoelectric transducer. Synthetic piezoelectric materials, such as barium zirconate, barium titanate, or lead mataniobate, are generally used. A sheet of piezoelectric material develops a voltage difference between opposite faces when subjected to mechanical bending. Thin electroplating on these surfaces allows an electrical connection to be made to the device so that this voltage can be measured. The voltage is proportional to the amount of mechanical bending or pressure change experienced by the receiver as resulting from seismic energy propagating through the water. Various types of hydrophones are available such as disk hydrophones and cylindrical hyrdophones.
Two types of seismic sources are used to generate seismic waves for the seismic measurements. The first source type comprises an impulsive source which generates a high energy, short time duration impulse. The time between emitting the impulse from the source and detecting the reflected impulse by a receiver is used to determine the distance to the subsurface structure under investigation. The impulsive source and the associated data acquisition and processing system are relatively simple. However, the magnitude of energy required by seismic techniques using impulsive sources may, in some situations, be harmful to marine life in the immediate vicinity of source 112.
The environmental concerns associated with impulsive sources has lead to the use of another type of seismic source which generates a lower magnitude, vibratory energy. The measurement technique which uses such a source is referred to as the marine vibratory seismic ("MVS") technique. Rather than imparting a high magnitude pressure pulse into the ocean in a very short time period, vibratory sources emit lower amplitude pressure waves over a time period typically between 5 and 7 seconds, but longer time periods are also possible. Further, the frequency of the vibrating source varies from about 5 to 150 Hz, although the specific low and high frequencies differ from system to system. The frequency of the source may vary linearly with respect to time or non-linearly. The frequency variations are commonly called a "frequency sweep". The frequency sweep is thus between 5 and 150 Hz and 5 to 7 seconds in duration. The magnitude of the seismic wave oscillations may vary or remain at a constant amplitude. The amplitude of the oscillations, however, are much lower than the magnitude of impulsive sources and thus, there are fewer environmental concerns with the MVS seismic technique.
Seismic ships must move forward while seismic measurements are being recorded for many reasons. Referring still to FIG. 1, the hydrophones 114, connecting wires and stress members provided on the streamers are placed inside a neoprene tube (not shown in FIG. 1) 2.5-5 inches in diameter. The tube is then filled with sufficient lighter-than-water liquid to make the streamer neutrally buoyant. A lead-in section 111 of the streamer 110 approximately 300 meters long and a number stretch of sections approximately 50 meters long trail between the ship's stern and the streamer section 116 in which the receivers 114 are included. A diverter 113 pulls the streamer section 116 out to an appropriate operating width. Depth controllers (not shown) are fastened to the streamer at various places along its length. These devices sense the hydrostatic pressure and tilt bird wings so that the flow of water over them raises or lowers the streamer to the desired depth. The depth that the controllers seek to maintain can be controlled by a signal sent through the streamer cabling and thus the depth can be changed as desired. For the streamer's depth control system to function effectively, the ship 100 must travel forward at a speed through the water of approximately four knots.
Second, streamer 110 usually is a flexible cable and thus the ship must move forward to maintain a desired fixed separation between the sources and streamers, and between the streamers themselves. The spacing between sources and streamers is important in the marine seismology and must not vary while seismic measurement are made.
Third, seismic ships often deploy multiple streamers using diverters that allow a fixed separation to be maintained between streamers. These diverters force the streamers laterally as the boat moves forward. Without the barvanes, the streamers may become entangled. The relative velocity of the water around the diverters and the angle of attack determine the amount of separation between streamers.
Fourth, seismic ships must cover as much ocean surface as possible each day because of the cost of operating the ship. For these reasons and others, seismic ships must move forward while taking measurements and the forward speed must be reasonably constant. Typical ship speed is approximately 2-3 meters per second. Because the streamer is deployed behind the ship, the source and receivers also move at approximately 2.5 meters per second.
Marine seismic measurements can also be made using a technique called "on-bottom cable" (OBC) in which a ship lays one or more cables containing hydrophones and geophones on the ocean floor. This ship remains stationary and records data while collecting seismic data. The second ship containing sources moves parallel, or at some other angle, to the cables. In the OBC technique, the receivers do not move, but the sources are moving and thus, the acquired data is distorted. Further, in special circumstances, some of the receivers can be on land. Although OBC is generally more expensive than towed marine seismic measurements, OBC is necessary if land obstructions, such as an island, are located where the cables are to be layed.
Although ship motion is necessary as described above, the motion distorts or "smears" the acquired seismic data. Broadly, smearing results from the fact that the ship, and thus the sources and receivers, move while data collection takes place. It is generally recognized that the smearing effect of ship motion on seismic data results from two analytically separate phenomena--source motion and receiver motion. Although the receivers and source are pulled behind the ship and thus move at the same speed as the ship, the effect of source motion on the data is usually analyzed independently from the effect of receiver motion. Source motion is less of a concern than receiver motion in impulsive source-based seismic systems because the source moves a negligible amount during the brief impulse emitted by the source. Data smearing in a MVS system includes significant contributions from both receiver and source motion. Thus, the MVS-acquired data should be corrected for both receiver and source motion.
The high costs associated with operating a seismic ship require that the methods and procedures used be efficient. It is thus desirable to maximize data collection in as short a time as possible. Because of the length of the frequency sweep (typically 5 seconds or more), MVS sources are typically activated every 10 to 20 seconds. Because of the ship's speed (2-3 meters per second), a MVS source must be activated no sooner than every 12.5 to 75 meters. Although more data in one location could be acquired if the ship were to travel at a slower speed, streamer control would be lost and less ocean surface would be covered each day, thereby increasing the cost required to make seismic measurements of a desired section of the subsurface.
At least one attempt has been made to correct for receiver and source motion for MVS recorded data. In an article entitled "The Effects of Source and Receiver Motion on Seismic Data," by Hampson and Jakubowicz, Geophysical Prospecting, 1995, p. 221-244, a method for correcting for receiver and source motion is disclosed. Although the method of Hampson and Jakubowicz has theoretical merit, the method is impractical for use with conventional marine seismic systems as it requires the MVS source to be activated with a temporal and spatial spacing that is impractical. It is well known that for a wave traveling with a velocity V through a medium such as water and with a frequency of F (i.e., the number of complete cycles of the waveform per second), the velocity V is related to the frequency F by the length of the wave, referred to as the wavelength (λ). The relationship is:
V=F·λ. (1)
Thus, the wavelength λ is V/F. In water seismic waves propagate with a known velocity of approximately 1500 meters per second (approximately 3325 miles per hour). If the highest frequency in a sweep is assumed to be 60 cycles per second (or 60 "Hz"), the wavelength of such a seismic wave is 25 meters (1500/60). To avoid a certain type of data distortion known as "aliasing", the source must be activated at a spacing of at least one half of the wavelength. Thus, for Hampson and Jakubowicz's method to work the vibratory sources must be activated at least every 12.5 meters, and preferably sooner. To activate a source at such narrow spacings, the ship must travel much slower than its preferred 2-3 meters per second.
It would be advantageous to provide a practical seismic system for use in marine applications that can correct the data for the motion of the ship without the deficiency inherent in the Hampson and Jakubowicz method. Such a system preferably would correct for both receiver and source motion and do so in a cost effective manner. Despite the apparent advantages, to date all attempts of developing such a system have failed.
BRIEF SUMMARY OF THE INVENTION
The problems outlined above are in large part solved by the seismic measurement and processing system of the present invention. The seismic measurement and processing system disclosed herein removes the distortion in marine seismic data resulting from the motion of the ship. According to the invention, the ship tows behind it one or more seismic sources and streamers as it moves forward at an approximately constant velocity. The seismic sources emit seismic waves that travel through the water and reflect off interfaces between rock formations at and below the ocean floor. The motion of the sources and receivers introduce distortion in the recorded seismic data that can be modeled using Doppler theory. The data preferably is corrected for source motion independently from the correction for receiver motion. According to the preferred embodiment, the seismic data is corrected first for receiver motion using any of a variety of techniques and then for source motion.
The technique for correcting for source motion includes correlating the receiver-corrected data with a reference sweep signal, performing a transform (such as an F-K transform), performing an inverse transform (such as an inverse F-K transform) on a selected subset of the transformed data, and computing appropriate correction filters for the data resulting from the inverse F-K transform. The inverse transformed data corresponds to seismic energy that travels upward from subsurface structures at a particular angle referred to as a dip angle. Appropriate Doppler correction filters are computed for each set of inverse transformed data and the process is repeated for all subsets of F-K transformed data. The Doppler filters are applied to the seismic data, and the filtered data are summed together.
These and other advantages of the present invention will be apparent to one skilled in the art upon reading the following detail description of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
A better understanding of the present invention can be obtained when the following detailed description of the preferred embodiment is considered in conjunction with the following drawings, in which:
FIG. 1 shows a ship for making seismic measurements with a towed streamer array including a seismic source and multiple receivers;
FIG. 2 shows a seismic measurement system in accordance with the preferred embodiment of the present invention;
FIG. 3 shows the preferred method of correcting seismic data for the distortion caused by motion of the source and receivers;
FIG. 4 shows exemplary pressure data from multiple receivers and the distorting effect of receiver motion on the data;
FIG. 5 shows a preferred method for correcting seismic data for the distortion caused by receiver motion;
FIG. 6 shows an exemplary plot of seismic data in the F-K domain;
FIG. 7 shows exemplary shot records of multiple receivers in which only data at a constant dip angle is included in the shot records;
FIG. 8 shows the relationship between apparent wave velocity and true wave velocity;
FIG. 9 shows the preferred method of constructing and applying Doppler shift filters to the shot records of FIG. 6;
FIG. 10 shows the geometry associated with a moving source, a single point diffractor, and a receiver for calculating the amount of Doppler shift caused by the moving source; and
FIG. 11 shows the preferred method for computing Doppler shift corrective filters for multiple diffractors.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention corrects seismic data collected by a marine seismic system for the motion of the towed seismic receivers and sources. For simplicity, the technique will be described with reference to a "diffractor" (also called a "scatterer") which is a reflecting point located at the physical interface between contiguous subsurface formations. Because a subsurface interface is comprised of many point diffractors, the entire interface can be mapped by merely superimposing the results from each point diffractor.
Referring now to FIG. 2, a seismic system 50 constructed in accordance with the preferred embodiment generally includes a seismic measurement and processing system 51, a user input device 59 (preferably a keyboard, buttons, switches, and control knobs), a display device 52, one or more seismic sources 112, and one or more cables (also called streamers) of seismic receivers 114. The collection of all receivers for a shot is also referred to as a "shot gather." The seismic measurement and processing system 51 includes a processing unit 53 coupled to a data storage unit 54, and source and receiver interface unit 56. It should be recognized that the seismic measurement system 50 may include other components not shown in FIG. 2. The user input device 59 allows a user to input commands and configuration information into the system 50. The display device 52 provides visual representations of data, configuration information, and status information to the user. The source and receivers preferably couple to the seismic measurement system via fiber-optic cables 57. The source 112 includes any suitable seismic source such as MVS sources and impulsive sources. Receivers 114 includes suitable hydrophone receivers including piezoelectric-based devices or any other suitable type of seismic receiver.
The processing unit preferably controls the operation of the seismic measurement system 50, storing data in storage unit 54 (which preferably is a magnetic tape, a hard disk. or CD ROM drive), and controlling the operation of the source 112 and receivers 114. Seismic signals detected by the receivers are transmitted to the seismic measurement system, processed by processing unit 52 and stored in storage unit 54.
Referring now to FIGS. 2 and 3, and explained in more detail in the discussion that follows, the seismic measurement and processing system 51 preferably corrects the recorded seismic data for the motion of the receivers 114 and the source 112 according to the methodology illustrated in flow chart 150. Alternatively, the seismic data can be stored on magnetic tape or disk and transferred to another computer system for analysis according to the teachings of the preferred embodiment at a location remote from the seismic ship. The preferred data correction method corrects first for the effect of receiver motion in step 160, and then corrects the data for the effect of source motion in steps 170-240. Each of these steps is explained below.
Correction for Receiver Motion (step 160)
Referring now to FIG. 4, a shot gather 114 of receivers 125, 126, 127, 128 is shown with a pressure signal 120 recorded by each receiver. The pressure signals 120 are referred to collectively as a "shot record." Time is represented along the vertical axis and distance is represented across the horizontal axis. An exemplary trace is shown for one receiver 125 and, for simplicity, a straight line is used to represent the remaining trace records.
If the receivers did not move while recording the shot records, the traces 120 would be recorded at a fixed location and therefore would be a function only of time, and not space. Because the receivers are towed behind a moving ship (assumed to be moving to the right in FIG. 4), each shot record is recorded as a function, not only with respect to time, but also space, as indicated by traces 122 for each receiver. Traces 122 represent traces 120 as the receiver is pulled behind the ship. Thus, each data point on the shot records 122 represents the seismic pressure signals sensed by the receiver at a particular point in time and space.
Referring still to FIG. 4, each receiver is assumed to be located at position r 0 when the shot record begins. Thus, receiver 125 begins at location r125 0 . Receiver 126 begins at location r126 0 , receiver 127 at location r127 0 , and receiver 128 at location r128 0 . The distance between the initial location r 0 and the ending position is a function of the speed of the receivers. It is assumed for purposes of this discussion that the speed of the receivers, as well as the speed of the sources, is the same as the speed of the ship, although in theory slight differences in the speeds may exist due to such factors as the elasticity of the streamer 110.
Shot records 122 are represented in FIG. 4 as straight diagonal lines. The lines (representing pressure waveforms) are straight because the receiver speed is assumed to be constant. If the receiver speed is u r , then the position of each receiver at any time t during a shot record is r 0 +u r t. The linear slanting of the shot records 122 is equivalent to a time-variant spatial shift. If p(s,u s ,S(t),r,u r ,t) represents the magnitude (pressure) p of the shot record as a function of source location s, source speed u s , seismic signal S(t) produced by the source, receiver location r, receiver speed u r , and time t, then time variant spatial shift can be mathematically modeled as the convolution of p(s,u s ,S(t),r,u r ,t) with a "Dirac" delta function (also referred to as a "unit impulse"):
p(s,u.sub.s,S(t),r=r.sub.0 +u.sub.r t,u.sub.r,t)=p(s,u.sub.s,S(t),r=r.sub.0,u.sub.r,t)*δ(r.sub.0 +u.sub.r t) (2)
where the * operator denotes convolution and δ denotes a delta function. The convolution of two functions (a function represents a series of values at various points in time or space) is a known mathematical operation which involves replacing each element of one function with an output function scaled according to the magnitude of the input element, and then superimposing the output values. For a more detailed explanation of convolution, reference can be made to "Exploration Seismology," by Sheriff and Geldart, published by the Press Syndicate of the University of Cambridge, 1995, p. 279-81.
The spatial shift represented by δ(r 0 +u r t) in equation (2) can be removed by convolving the result in equation (2) with a spatial shift in the opposite direction. The correction for receiver motion is therefore:
p(s,u.sub.s,S(t),r.sub.0,0,t)=p(s,u.sub.s,S(t),r=r.sub.0 +u.sub.r t,u.sub.r,t)*δ(r.sub.0 -u.sub.r t) (3)
In equation (3), convolution of the spatially shifted shot record with the delta function δ(r 0 -u r t) results in a shot record had the receiver been stationary (u r =0) at position r 0 . Thus, the effect of receiver motion on the shot record is neutralized by convolving the shot record with a delta function representing a spatial shift. It should be recognized that the foregoing analysis involves functions and mathematical operations that occur as functions of time and space (the so called time and space domains).
Other ways to correct the shot records for receiver motion are available. For example, the correction provided in equation (3) can also be represented in the frequency domain in which all functions vary with frequency, not time. Functions can be converted from their time and space domain representations to the frequency domain using a mathematical operation called a Fourier transform. The frequencies involved with such Fourier transforms include temporal and spatial frequencies. The Fourier transform of the delta function, δ(r 0 -u r t), is e -i2 πku.sbsp.r t where i represents the imaginary number (the square root of -1), k represents the spatial frequency (also referred to as the wavenumber) and π is a known constant. It is well known that convolution in the time and space domains is equivalent to multiplication in the frequency domain. Thus, the spatial shift introduced in equation (3) to counterbalance the spatial shift caused by the receiver motion can be represented in the frequency domain as the product of the Fourier transforms of the shot record and e -12 πku.sbsp.r t .
P(f,k)·e.sup.-i2πKu.sbsp.r.sup.t (4)
Where P(f, k) is the Fourier transform of the shot record and is a function of temporal frequency f and spatial frequency k. The symbol "·" denotes multiplication.
Referring now to FIGS. 2, 3 and 5, the seismic measurement system 50 removes the effect of receiver motion using equation (4) by first computing the Fourier transform of the shot records in step 162. The seismic measurement and processing system 51 computes the Fourier transform using any one of a variety of known techniques such as the Fast Fourier Transform. It should be recognized that any suitable transform, such as Laplace, radon, and τ-p transforms, can be used as well. In step 164, the seismic measurement and processing system 51 multiplies the Fourier transform of the shot records by the Fourier transform of the delta function of equation (3) represented as e -12 πKu.sbsp.r t . Finally, in step 166, the product from step 164 is converted back into the time and space domain through an operation referred to as the inverse Fourier transform which also is a known technique.
Another method for correcting for receiver motion is described with reference to FIG. 4 to correct the shot record for the motion of the receivers. This method will be described with reference to one such receiver, such as receiver 127. In this method, the seismic measurement and processing system 51 selects data from a receiver while the receiver is near the location at which the shot record is to be fixed. To fix the shot record for location r127 0 , for example, the seismic measurement system selects the portion of shot records from receivers 127, 126, and 125 when each receiver is near location r127 0 . The portion of the shot records to be selected by seismic measurement and processing system 51 is identified by reference numbers 127a, 127b, and 127c. Thus, seismic measurement system selects the initial portion 127a of the shot record from receiver 127 until that receiver moves a distance approximately equal to one-half the group interval away from location r127 0 . At that point, seismic measurement and processing system 51 selects the middle portion 127b of the shot record from receiver 126 until that receiver also moves one-half the group interval away from location r127 0 . Finally, the last portion 127c of the shot record from receiver 125 is selected by the system 51. The technique described above for correction of receiver motion is not needed if the OBC seismic technique is used.
The methods described above are exemplary only of the methods for correcting for receiver motion and the invention is not intended to be limited to any particular method. Preferably following receiver motion correction, the seismic measurement and processing system 51 corrects the data for the source motion.
Correction for Source Motion (steps 170-240)
Referring to FIG. 3, in the preferred method 150 for correction of the data for source motion, the seismic measurement and processing system 51 correlates the data (now corrected for receiver motion per step 160) with the MVS reference sweep signal. The MVS reference sweep signal can be any sweep signal desired and may include linear frequency sweeps (frequency changes at a constant rate during the sweep) or non-linear frequency sweeps (frequency changes at a varying rate during the sweep). As explained below, the correlation step 170 is necessary in a MVS system to compress the relatively long sweep to a short duration event.
The earth can be thought of as a filter of seismic energy. That is, if seismic energy is input into the earth, a receiver positioned on the surface of the earth will receive seismic energy whose character has been altered by the earth. The various factors that modify the seismic wave as it passes through the earth include:
(a) the zone near the source where the stresses and absorption of energy often are extreme;
(b) the response of the diffractors comprising the subsurface interfaces (the signal that seismic work is intended to find);
(c) the near-surface zone, which has a disproportionate effect in modifying the wave; and
(d) additional modifying effects because of absorption, wave conversion, multiples, and diffractions, and the like.
In practice, the receivers record not only primary seismic reflections, but also multiples, diffractions, scattered waves, reflected refractions, surface waves, and the like, all overlapping in time.
Generally, a filter is a system that produces an output signal for a given input signal. The output signal can be calculated if the impulse response for the filter is known. The impulse response is the output signal produced by the filter for a given impulse input signal. The output signal is simply the input signal convolved with the impulse response of the filter.
The seismic signal detected by the receivers represents the input reference signal influenced by the factors described above. Seismic data (or "seismograms") is useful to determine the location of oil and gas reservoirs when the data represents the input reference signal acted upon only by the diffractors comprising the subsurface interfaces, as contrasted with a reference input signal that is also influenced by the above-described signal altering factors. The effect that the diffractors have on the seismic waves propagating through the earth is referred to as the impulse response of the earth. Because of the additional signal altering factors described above, the seismic signal received by the receivers in a MVS recording bears little resemblance to the impulse response of the earth. Seismic work is intended to determine the impulse response of the earth, and thereby remove the influences on the data that are not of interest to seismologists.
To remove the long sweep duration from the recorded data, the seismic measurement system 50 preferably correlates the recorded data with the reference sweep signal. The correlation of two data sets is a known mathematical operation in which one data set is displaced by varying amounts relative to the other data set and corresponding values of the two sets are multiplied together and the products summed to give the value of the correlation. In step 170, shown in FIG. 3, the data from step 160 that has been corrected for receiver motion is correlated with the reference sweep signal.
In step 180, an F-K transform (F refers to temporal frequency and K refers to spatial frequency or wavenumber) is performed on the correlated data from step 170, although other suitable transforms, such as the Laplace transform, radon transform and τ-p transform, can also be used. The F-K transform is a double Fourier transform in which a signal that is a function of time, t, and space, x, is transformed to a signal that is a function of frequency, f, and wavenumber, k. The transformed signal can be plotted on a plot referred to as an F-K plot, such as that shown in FIG. 6. Converting a function from the time and space domain into the frequency and wavenumber domain is referred to as a forward F-K transform. By analogy, converting a function from the frequency and wavenumber domain back into the time and space domain is referred to as an inverse F-K transform. The forward F-K transform is represented mathematically with a double integral as:
P(k, f)=∫∫p(x,t)e.sup.-i2π(kx+ft) dxdt (5)
where P(k,f) is the F-K transform of p(x,t). The inverse F-K transform (performed in step 200) is represented as:
p(x,t)=∫∫P(k,f)e.sup.-i2π(kx+ft) dkdf (6)
Referring again to FIG. 3, in step 190, the seismic measurement system selects a constant time dip slice of data (described below) from the F-K plot. This step is best understood with reference to FIGS. 6, 7, and 8. FIG. 6 shows an F-K plot of a transformed shot record from FIG. 7. Frequency measured in cycles per second or "Hertz" (Hz) is represented on the vertical axis and wavenumber measured in cycles per meter is represented on the horizontal axis. The F-K transformed data is represented by portions 191 in the F-K plot.
Every straight line, such as lines 194, 195, 196, beginning from the origin of the F-K axes and extending outward represents seismic data with a particular apparent velocity. Further, the slope of each such straight line is equal to an apparent velocity. Referring to FIG. 7, receivers 125, 126, 127, 128 are shown with a seismic wave 132 propagating through the earth (including water) in the direction of arrow 129. Line 130 represents the direction of propagation of seismic wave 132 and forms an angle with vertical line 134. That angle is referred to as the angle of approach, apparent dip angle, or simply dip angle and is denoted in FIGS. 7 and 8 as θ DIP . Line 130 thus is referred to as the dip line or line of approach for purposes of this application.
Referring to FIG. 8, straight line 133 is perpendicular to dip line 130 and represents schematically the wavefront of waves 132 as they travel upward at the dip angle θ DIP . The wavefront 133 propagates up through the earth with a certain velocity referred to as the true velocity, V true . The true velocity of seismic waves propagating through water is approximately 1500 meters per second (3325 miles per hour), and in general is considered to be a constant. True velocities can be easily determined using any one of a variety of known techniques.
Referring to FIG. 8, the horizontal component of the true velocity vector is referred to as the apparent velocity, V app . The apparent velocity, V app , is:
Vapp=Vtrue/sin(θ.sub.DIP). (7)
Where "sin" is the trigonometric sine function. The apparent velocity has physical significance in that it is the horizontal velocity of the seismic wave 132 as detected by the receivers. As wavefront 133 moves upward, receiver 128 will detect the wavefront before receiver 127 detects it. Further, because of the distance between receivers 127 and 128 and the time interval between when the wavefront is detected by receiver 128 then receiver 127, the wavefront will appear to be traveling horizontally with velocity V app .
As can be seen by equation (7), V app is inversely proportional to the sine of the dip angle θ DIP , given that V true is a constant. Thus, each straight line in the F-K plot of FIG. 6, the slope of which is V app , defines a dip angle, θ DIP in FIGS. 7 and 8. Moreover, data in the F-K plot of FIG. 6 along a straight line, such as line 195, represents only the seismic energy that propagated up through the earth at a particular dip angle, and excludes seismic energy propagating upwards at all other dip angles.
Referring now to FIGS. 3, 6, and 7, the seismic measurement and processing system 51 preferably corrects the data for source motion by selecting a constant time dip slice of data from the F-K domain in step 190 (FIG. 3). An exemplary constant time dip slice is shown in FIG. 6 as the portion of data 191 bounded by straight lines 194 and 196. Because lines 194 and 196 define a pie-shaped wedge in the F-K plot, the data contained between lines 194, 196 is referred to as a constant time dip slice or pie slice. By selecting a pie slice of F-K data and inverse F-K transforming the selected pie slice data in step 200, the seismic measurement and processing system 51 selects only the seismic energy that propagates upward through the earth within a range of dip angles defined by the slopes of lines 194 and 196. Thus, according to the preferred embodiment of the invention, a constant time dip slice of F-K data is selected in step 190 and inverse F-K transformed in step 200. The size of the pie slice can be set to whatever size is desired and is generally a function of the accuracy desired. The size of the pie slice thus relates to a range of dip angles, θ DIP ±Δθ DIP .
The result of step 200 is a shot record that has been corrected for receiver motion and that represents the seismic energy that corresponding to a range of dip angles θ DIP ±Δθ DIP that are related as described above to the apparent velocity defined by the pie slice. It should be recognized that the seismic energy at dip angle θ DIP includes a superposition of seismic waves that have reflected off millions of diffractors along line 130. Using principles grounded in classical Doppler theory, the data can be corrected for source motion.
To understand the application of Doppler theory, reference is made to FIG. 7 in which a source 112 moves from location s 0 at the beginning of the MVS frequency sweep to location s end at the end of the frequency sweep. Point diffractors 140, 142, 144 represent exemplary diffractor locations along line 130. Lines 145 and 146 represent the direction seismic waves travel from the initial source location s 0 and the ending source location s end , respectively, to point diffractor 140. Similar lines can be drawn for seismic waves traveling to diffractors 142, 144. The seismic waves reflected by diffractors 140, 142, 144 travel upward along line 130 with dip angle θ DIP .
As shown, the source 112 moves from left to right and thus moves away from diffractor 140. Because the source moves away from the diffractor, the period of the emitted frequency sweep source signal will appear longer. Alternatively, the length of the frequency sweep will appear to be longer from the vantage point of diffractor 140. This change in frequency and length of the frequency sweep is referred to as frequency shift under Doppler theory. In this example, however, the source approaches diffractor 144 during the frequency sweep, and thus the frequency sweep becomes shorter from the vantage point of diffractor 144. Diffractor 142 is below the midpoint of the source's trajectory as it moves during the frequency sweep, and thus there is zero net frequency shift associated with diffractor 142. Moreover, the distortion due to source motion can be represented by the magnitude of the frequency shift using Doppler theory. As will be seen below, the magnitude of the Doppler shift can be computed for each diffractor location, or range of diffractor locations, and appropriate filters can be designed to correct the data for the distortion.
Referring now to FIG. 9, the preferred steps 210 to compute and apply Doppler correction filters to correct for source motion includes first computing the magnitude of the distortion in step 212. Because the Doppler frequency shift alters the length of the frequency sweep at each diffractor location, the magnitude of the distortion due to source motion can be represented by computing the change in the length of the frequency sweep for each diffractor. The change in length in the frequency sweep, measured in units of milliseconds, is referred to as dilation (or compression) and thus, in step 212 the dilation is computed for each diffractor. The dilation varies with diffractor location and is thus divided into time gates in step 214 so that the seismic measurement and processing system 51 can provide a correction filter for each time gate in step 216. Finally, in step 218 the seismic measurement and processing system 51 applies the correction filters to the shot record to correct for the dilation.
Referring now to FIG. 10, the geometry associated with deriving the dilation for a diffractor 140 includes source 112 moving from an initial location s 0 at the beginning of a frequency sweep to an ending position s end at the end of a frequency sweep. Diffractor 140 is located at a depth Z below the stationary receiver 127 and distance X away from the receiver. The distance H represents the distance between the receiver and the source 112 at its initial position s 0 . The angle θ r is the angle from dip line 130 to the horizontal axis. Angle θ r is related to the dip angle θ DIP as θ r =90-θ DIP . Thus, once a constant pie slice of data is selected from the F-K domain, θ r is defined. Seismic waves from the source at location s 0 travel along line 145 in the direction indicated, reflect off diffractor 140 and travel along line 130 to a receiver 127. Similarly, a seismic wave emitted by the source 112 at position s end travel along line 146 in the direction indicated, and reflect off diffractor 140 and also travel along line 130 to receiver 127. The amount of dilation is calculated as the difference between the time a seismic wave takes to travel from the source 112 at its initial position s 0 to receiver 127 and the time a wave takes to travel from the source to the receiver when the source is at its ending position s end . Recognizing that the seismic waves take the same amount of time to travel along line 130 between the diffractor 140 and receiver 127 (or after correction for receiver motion), the dilation is simply the difference in time a wave takes to travel from the source 112 at location s 0 along line 145 to the diffractor 140, and the time of travel from the source at location s end to the diffractor along line 146. If T s0 represents the former the time along line 145 and T s end represents the time along line 146, then the dilation is:
DIL=T.sub.s end -T.sub.s0 (8)
where DIL is the amount of dilation. The dilation value DIL thus is positive when T s end is greater than T s0 (i.e., when the source is moving away from the diffractor) and negative when T s end is less than T s0 (source is moving toward the diffractor).
Referring still to FIG. 10, and applying the Pythagorean theorem: ##EQU1## where V is the propagation velocity of seismic waves in water (1500 meters/second), T is the time a seismic wave takes to travel from the source at s0 along line 145 to diffractor 140 and along dip line 130 to receiver 127. Equation (9) can be rewritten as a quadratic equation and thus can be ##EQU2## solved for X: where:
C=H.sup.4 +V.sup.4 T.sup.4 -2H.sup.2 V.sup.2 T.sup.2 (12)
A=4(H.sup.2 -V.sup.2 T.sup.2 [1+tan.sup.2 (θ.sub.r)])(13)
B=4H(V.sup.2 T.sup.2 -H.sup.2) (14)
As shown in FIG. 10, the conventions are: horizontal distance away from the source to the receiver is +X; distance down from the source is +Z; and the dip angle, θ r , is measured from the negative x-axis in a clockwise direction. For θ r less than or equal to 90°, the negative sign in equation (11) is used and for θ r greater than 90°, the positive sign in equation (11) is used. Using equation (11), X can be calculated at time T, and once X is known, Z can be calculated using equation (10). Calculating X and Z for each constant θ r provides the location of a diffractor for a seismic event at time T.
Equation (8) can be rewritten as: ##EQU3## where u s is the source velocity and T SL is the time length of the frequency sweep. As can be seen by examination of equations (11)-(15), the dilation DIL is a function of the location of a diffractor (X and Z), T, boat speed u s , and the length of the frequency sweep T SL . Further, equation (14) only has a solution when T>H/V.
Referring now to FIGS. 9 and 11, a plot of dilation DIL as a function of time is shown for a source 112 and a receiver 127. As shown, positive DIL values are plotted to the right of axis 188 with negative DIL values to the left of the axis. Although, correction filters can be calculated on a sample-by-sample basis (which may be preferred), satisfactory results can be achieved in less time if the dilation curve is divided into segments and correction filters are constructed for each segment, rather than for the samples that comprise the segments. Thus, according to the preferred embodiment, dilation DIL is discretized into segments 252, 253, 254, 255 and associated time gates 256, 257, 258, 259, 260. The size of segments 252-255, and thus the size of time gates 256-260, can be set to any desired size.
Numerous techniques are available to construct appropriate filters to compensate the shot records for the amount of dilation in each time gate. For example, the sweep can be resampled to Δt' where ##EQU4## where Δt is the sampling period for the shot record. After resampling, the new sample rate is overruled and called Δt providing a new shot record. As an exaggerated example, for a 1 second sweep dilated by 1 second and sampled at a 2 millisecond rate (one sample taken every 2 milliseconds), the sweep is resampled to 1 millisecond providing twice as many samples. The resampled data is then given a sample rate of 2 milliseconds making the record twice as long. The dilated sweep is then correlated with the non-dilated sweep. The phase of the result is the required phase correction.
The phase component of the data is non-zero due to the Doppler shifts which result from the ship's motion. Moreover, the major effect of the distortion due to source motion is seen only in the phase spectrum of the data. The distortion can be eliminated by forcing the phase component of the data to a constant value, preferably zero phase. Thus, in accordance with the preferred embodiment, the seismic measurement and processing system 51 extracts the phase component of the dilation model cross-correlated with the reference sweep. A standard all-pass inverse filter, such as can be obtained using the Wiener-Levinson technique, is selected to eliminate the phase content of the recorded data after correlation with the reference sweep signal. An all pass inverse filter does not alter the amplitude content of the data, rather only the phase content. The filter preferably is constructed to remove the phase content, causing the output signal from the filter to have zero phase. An all-pass inverse filter provides an exact solution.
Often, however, the phase error as a function of frequency can be approximated by a phase intercept angle and a phase slope term. Such an approximation to the phase error can be used to sufficiently eliminate the phase error. Additionally, other types of approximations, including higher order approximations, can be used as well. Such approximations permit a practical (i.e. less expensive) implementation than using an all-pass inverse filter.
The correction filters preferably are applied to the entire trace of data and then the appropriate segments from each corrected trace are selected and combined together to form a completely corrected data set. Thus, the correction for the data for a time gate of 1 second, for example, is applied to the data. Similarly, the corrections for time gates of 2 seconds, 3 seconds, 4 seconds, and so on, are also applied to the data set, thereby generating four data sets each corrected by a particular correction filter. Then, only the corrected data from 0 to 1.5 seconds is selected from the first data set, the corrected data from 1.5 to 2.5 seconds is selected from the second data set, the corrected data from 2.5 to 3.5 seconds is selected from the third data set, the corrected data from 3.5 to 4.5 seconds is selected from the fourth data set, and so on.
After correcting the seismic data for receiver and source motion for a constant dip slice in step 210 (FIG. 3), the next dip slice of F-K data is selected in step 240 and steps 200-210 are repeated until all of the F-K data has been selected. Once all the data has been corrected for each dip slice of F-K data, the results are summed in step 230 to produce the desired data corrected for source and receiver motion.
Numerous variations and modifications will become apparent to those skilled in the art once the above disclosure is fully appreciated. It is intended that the following claims be interpreted to embrace all such variations and modifications. | An apparatus and method for removing the distortion in marine seismic data resulting from the motion of the ship. The ship trails one or more seismic sources and receivers and moves forward at a known velocity. The seismic sources emit seismic waves that travel through the water and reflect off interfaces between rock formations below the ocean floor. The motion of the sources and receivers introduces distortion in the recorded seismic data that can be modeled using Doppler theory. The data preferably is corrected for source motion independently from the correction for receiver motion. The seismic data is first corrected for receiver motion and then for source motion. The technique for correcting for source motion includes correlating the receiver-corrected data with a reference sweep signal, performing an F-K transform, performing an inverse F-K transform on a selected subset of the F-K transformed data, and computing appropriate correction filters for the data resulting from the inverse F-K transform. This process is repeated for all subsets of F-K transformed data and the resulting filtered data are summed together. | 6 |
BACKGROUND OF THE INVENTION
1. Field of Invention
This invention relates generally to read-only memories (ROMs) and a method for manufacturing the same, and more particularly to ROMs and a manufacturing method for ROMs having a trench-type gate structure buried within a substrate and a source/drain terminal structure formed above the substrate.
2. Description of Related Art
ROMs are widely used in digital equipment such as microcomputers and microprocessor operating systems. ROMs normally store resident programs, such as BIOS used by operating systems. ROM manufacturing processes involve time-consuming steps and material processes. Generally, ROM customers submit program codes to a ROM manufacturer, and the ROM manufacturer encodes the program codes into the ROM during manufacturing.
Despite the different program codes stored during manufacturing, most ROMs have identical physical structures. Therefore, ROM manufacturers complete ROM manufacturing to a state immediately before actual programming, and then store the partially finished ROMs in a warehouse. When customers order ROMs requiring a particular program code, the manufacturer creates a set of photomasks and subsequently program,s the partially-finished ROMs in inventory with the program code provided by the customer. This procedure of photomask programming a prefabricated ROM has become the norm in the semiconductor manufacturing industry.
Generally, a basic memory cell unit of a ROM comprises a channel transistor. During the programming phase, ions are selectively implanted into specified channels of the channel transistor, adjusting the threshold voltage thereof and achieving ON/OFF control of the memory cell unit. FIGS. 1A-1C show the manufacturing steps involved in the creation of a conventional ROM. FIG. 1A is a partial top view, FIG. 1B is a partial front view, and FIG. 1C is a partial cross-sectional side view of the conventional ROM. As shown, the conventional ROM includes a substrate 10, such as, for example, a P-type silicon substrate, having a plurality of bit lines 11, an oxide layer 12 and a plurality of word lines 13 formed on a top surface of substrate 10. Referring to FIG. 1A, areas 14 enclosed by the rectangular dash lines comprise the memory cell units. Whether or not ions are implanted into a channel 16 of the memory cell unit determines if the memory cell unit contains a binary bit of "0" or "1", respectively.
As shown in FIG. 1C, N-type impurities, such as arsenic ions, are implanted into substrate 10 forming the plurality of equidistant bit lines 11, wherein the areas between two bit lines 11 constitute channel regions 16. Next, an oxidation process forms an oxide layer 12 on the surface of bit lines 11 and channel regions 16. A conductive layer, such as for example, a heavily doped polysilicon layer, is subsequently formed, followed by photolithographic and etching processes that form word lines 13 crossing over bit lines 11, and thus form the completed prefabricated conventional ROM.
In the programming phase of manufacturing the conventional ROM, program codes are encoded in the ROM by forming a masking layer 15 on the surface of word lines 13 that exposes channel regions 16 to be encoded. The programming phase is complete upon implantation of P-type impurities, such as, for example, boron ions, in the exposed channel regions 16. Different doping sources may be used during the programming phase so to obtain different properties for the transistors.
FIGS. 2A and 2B show another conventional ROM. FIG. 2A is a partial top view and FIG. 2B is a cross-sectional side view of the second conventional ROM. The area 24 within the rectangular dash lines of FIG. 2A comprises the memory cell unit. The manufacturing method for the conventional ROM shown in FIGS. 2A and 2B comprises the steps of implanting N-type impurities, such as, for example, arsenic ions, into a substrate 20 forming a plurality of equidistant source/drain terminals 21, wherein the area between two source/drain terminals 21 constitutes a channel region 25. A subsequent step comprises encoding program codes in the ROM by exposing channel regions 25 to be encoded to implantation of P-type impurities, such as, for example, boron ions. A further step includes forming an oxide layer 22 and a conductive layer, such as a heavily doped polysilicon layer. Thereafter, the method comprises the step of forming the conductive layer into word lines 23, constituting channel transistors, by using photolithographic and etching processes. A subsequent step includes forming an insulating layer 27 on word lines 23 and providing a plurality of contact window openings 28 in the insulating layer 27, wherein a bottom portion of the plurality of contact window openings 28 is connected to source/drain terminals 21. Finally, the method comprises the step of forming contact windows 26 by filling the plurality of contact window openings 28 with a metal, such as aluminum.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide a ROM and method for manufacturing a ROM that is planar and in which current is prevented from leaking between source/drain regions and a substrate.
Additional objects and advantages of the invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. The objects and advantages of the invention will be realized and attained by means of the elements and combinations particularly pointed out in the appended claims.
To achieve the objects and in accordance with the purpose of the invention, the invention comprises method for manufacturing a read-only memory, comprising the steps of: forming a pad oxide layer over a first conductivity-type substrate; forming a photoresist layer on a surface of the pad oxide layer, defining a pattern on the photoresist layer and forming a plurality of parallel trenches in the substrate along a first direction; performing a first ionic-type doping operation using the photoresist layer as a mask to form a plurality of barrier insulating layers, wherein the photoresist layer is removed thereafter; forming a first insulating layer over surfaces of both the substrate and the plurality of parallel trenches; forming a first conductive layer over a surface of the first insulating layer to fill the plurality of parallel trenches; etching the first conductive layer until heights of the first conductive layer and the substrate surface are substantially the same; removing the first insulating layer and the pad oxide layer exposed on the top surface of the substrate so to expose the top surface of the substrate; forming a second insulating layer over the top surfaces of both the substrate and the first conductive layer; forming a second conductive layer over a top surface of the second insulating layer; annealing the second conductive layer; and implanting ions on a surface of the second conductive layer so to adjust a threshold voltage of the second conductive layer. The method further comprises the steps of: defining a pattern on the second conductive layer and forming a plurality source/drain regions parallel along a first direction and a plurality of channel regions parallel along a second direction and being connected to the source/drain regions, wherein the first direction crosses the second direction at an angle, and a plurality of openings are formed in middle portions of intersections of the plurality of source/drain regions and the plurality of channel regions; forming a third insulating layer that fills the plurality of openings; implanting ions of a second ionic type into the source/drain regions; performing an encoding operation by implanting ions into select ones of the plurality of channel regions; forming a planar fourth insulating layer above the top surfaces of the first conductive layer ad the third insulating layer; patterning the fourth insulating layer to forming a plurality of gate region contact windows exposing the first conductive layer and a plurality of source/drain region contact windows exposing the plurality of source/drain regions; and forming a third conductive layer in the plurality of gate region contact windows and the plurality of source/drain region contact windows so to form a plurality of gate region electrodes and a plurality of source/drain region electrodes, respectively.
In accordance with another aspect, the present invention comprises a read-only memory comprising: a substrate having a plurality of parallel trenches extending in a first direction; a plurality of barrier insulating layers within the substrate and surrounding the plurality of parallel trenches; a first insulating layer formed on a surface of the plurality of parallel trenches; a plurality of gate regions formed in the plurality of parallel trenches, wherein the plurality of gate regions represent word lines; a second insulating layer formed on the surfaces of the substrate and the plurality of gate regions; a first conductive layer arranged in a checkerboard fashion above the second insulating layer, the first conductive layer comprising of a plurality of source/drain regions running parallel along a first direction and a plurality of channel regions located above the plurality of gate regions, running parallel along a second direction and being connected to the plurality of source/drain regions, wherein the plurality of source/drain regions act as bit lines, the threshold voltages of the plurality of channel regions are adjustable, the first direction crosses the second direction at an angle, and a plurality of openings expose a portion of the second insulating layer are formed in middle portions intersections of the plurality of source/drain regions and the plurality of channel regions; a third insulating layer filling the plurality of openings; a fourth insulating layer above the surfaces of both the first conductive layer and the third insulating layer; a plurality of gate region contact windows formed in the fourth insulating layer to expose a portion of the plurality of gate regions; a plurality of source/drain region contact windows formed in the fourth insulating layer to expose a portion of the plurality of source/drain regions; a plurality of gate region electrodes formed in the plurality of gate region contact windows and on the surface of the fourth insulating layer so to surround the plurality of gate region contact windows; and a plurality of source/drain region electrodes formed in the plurality of source/drain region contact windows and on the surface of the fourth insulating layer so to surround the plurality of source/drain region contact windows.
It is to be understood that the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings are included to provide a further understanding of the invention and are incorporated in and constitute part of the specification, illustrate preferred embodiments of the invention, and, together with a description, serve to explain the principles of the invention.
FIG. 1A is a partial top view of a conventional ROM;
FIG. 1B is a cross-sectional front view of the conventional ROM of FIG. 1A;
FIG. 1C is a cross-sectional side view of the conventional ROM of FIG. 1A;
FIG. 2A is a partial top view a another conventional ROM;
FIG. 2B is a cross-sectional side view of the conventional ROM of FIG. 2A;
FIGS. 3A-3M show a method for manufacturing a ROM in accordance with a preferred embodiment of the present invention; and
FIG. 4 is a partial top view of the ROM fabricated according to the preferred embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Reference will be made in detail to the present preferred embodiment of the invention, an example of which is illustrated in the accompanying drawings. Like reference numerals refer to like parts in the various figures of the drawings.
Referring to FIG. 3A, a planar silicon substrate or another electrically-insulating material is provided as a base for the ROM of the preferred embodiment. In this embodiment, a P-type N-type silicon substrate is used, and a thermal oxide method, for example, forms a pad oxide layer 32 of silicon dioxide on substrate 30. A photoresist layer 35 is then coated on pad oxide layer 32, and a photolithography method defines gate regions are photolithographically defined in photoresist layer 35. Subsequently, a dry etching process, such as, for example, a reactive ion etching process, etches substrate 30, oxide layer 32 and photoresist layer 35 to form a plurality of substantially parallel trenches 34.
As shown in FIG. 3B, ions, P-type ions, or N-type ions are implanted, using photoresist layer 35 as mask, to form a plurality of barrier layers 36 on the sides and the bottom of the trenches 34. The photoresist layer 35 is subsequently removed.
Referring to FIG. 3C, a thermal oxide method or a chemical vapor deposition (CVD) method, for example, forms an insulating layer 38 over the surface of substrate 30 and in trenches 34. A conductive layer 40 is then formed over the surface of insulating layer 38, filling trenches 34. The conductive layer 40 may be, for example, a heavily doped polysilicon layer, formed by a CVD method.
As shown in FIG. 3D, a subsequent step of the method of the present invention comprises removing conductive layer 40 with an anisotropic etching process or a chemical-mechanical polishing method until the surfaces of conductive layer 40 and substrate 30 are substantially the same height. Thereafter, an exposed portion of insulating layer 38 and pad oxide layer 32 are removed to expose the top surface of substrate 30, wherein conductive layer 40 remains in trenches 34 and constitutes gate regions having a bottom portion separated from substrate 30 by insulating layer 38.
Referring to FIG. 3E, a CVD method forms an insulating layer 42 comprising, for example, a silicon dioxide layer or a silicon nitride layer, over exposed surfaces of substrate 30 and conductive layer 40, wherein insulating layer 42 acts as a gate oxide layer. A conductive layer 44 is then formed over a top surface of insulating layer 42, and is annealed using, for example, a rapid thermal annealing (RTA) process so to activate grain regrowth of crystal grains inside conductive layer 44. The conductive layer 44 is a polysilicon layer or a monocrystalline silicon layer. Next, ions, such as, for example, N-type or P-type ions, are implanted into conductive layer 44 to adjust a threshold voltage of conductive layer.
As shown in FIG. 3F, photolithographic and etching processes define and etch, respectively, a pattern in conductive layer 44, exposing insulating layer 42 and forming a plurality of parallel source/drain regions 46 and a plurality of parallel channel regions 47 connected to the plurality of source/drain regions 46. The source/drain regions 46 and the channel regions 47 cross each other at an angle of, preferably, ninety degrees, and a plurality of openings 45 are provided in middle portions of intersections of the plurality of source/drain regions 46 and the plurality of channel regions 47. Thus, the plurality of source/drain regions 46 and the plurality of trenches 34 form a checkerboard pattern.
Referring to FIGS. 3G and 3H, an insulating layer 48 is formed above conductive pattern and in the plurality of openings 45. Insulating layer 48 preferably comprises, for example, a silicon dioxide layer or a silicon nitride layer formed by a CVD method or a spin-on glass method. Thereafter, an anisotropic etch-back method or a chemical-mechanical polishing method, for example, flattens or planarizes insulating layer 48 using the plurality of source/drain regions 46 and the plurality of channel regions 47 as an etch or polishing end point, wherein a residual portion of insulating layer 48 remains in openings 45.
A photoresist layer 49, as shown in FIG. 3I, is coated above insulating layer 48 and conductive layer 44, and then a photolithographic technique patterns photoresist layer 49 such that the plurality of source/drain regions 46 are exposed. Next, using photoresist layer 49 as a mask, the plurality of source/drain regions 46 are doped with highly concentrated ions, preferably N-type ions, or P-type ions lowering resistances of the plurality of source/drain regions 46 so to obtain a plurality of N + source/drain regions 46. The photoresist layer 49 is subsequently removed, completing the prefabrication portion of the manufacturing method of the present invention Referring to FIG. 3J, the program encoding portion of the method comprises the steps of forming a photoresist layer 50 on conductive layer 44, and defining photoresist layer 50 with a photolithographic process, exposing designated OFF channel regions 47. With photoresist layer 50 acting as a mask, exposed designated OFF channel regions 47 are ion implanted using, for example, P-type ions. Photoresist layer 50 is subsequently removed, completing the program encoding portion of the method. Memory units having channel regions implanted with ions become OFF state memory units, such as memory unit 100, while memory units in which ion implantation is prevented due to the masking photoresist layer become ON state memory units, such as memory unit 102.
As shown in FIG. 3K, subsequently source/drain and gate region contact windows are formed by coating an insulating layer 51 over a top surface of the device. Insulating layer 51 preferably comprises, for example, a planar insulating layer such as a silicon oxide layer, a silicon nitride layer, or a boro-phosilicate glass layer. A pattern is then defined in the insulating layer 51, followed by removal of exposed portions of insulating layer 48, thereby forming a plurality of gate region contact window openings 52 exposing gate regions 40 and a plurality of source/drain region contact window openings 53 exposing source/drain regions 46.
FIG. 3L is a cross-sectional view taken along line 3L--3L of FIG. 3K. As shown in FIG. 3L, a metal, such as aluminum, is provided in the plurality of gate region contact window openings 52 and the plurality of source/drain region contact window 53 to form gate electrodes 54 and source/drain electrodes 55, respectively. The final configuration of the ROM in accordance with the preferred embodiment of the present invention is shown in FIG. 3M. Since subsequent ROM manufacturing processes indirectly relate to the present invention, a detailed description of these processes have been omitted.
A P-type substrate was used in the preferred embodiment of the present invention, described above. However, the present invention may be equally applied to an N-type substrate. When an N-type substrate is used, all the aforementioned processes using N-type ions have to be replaced with P-type ions, while those processes using P-type ions have to be replaced with N-type ions.
A partial top view of the ROM fabricated according to the preferred embodiment of the present invention is shown in FIG. 4. In the FIG. 4, the portion within the dashed lines labeled 100 is an OFF state memory unit while the portion within the dashed lines labeled 102 is an ON state memory unit.
The preferred embodiment of the ROM of the present invention comprises several advantages. Specifically, by employing the trench-type gate region in the substrate and by isolating the gate region from the substrate and the source/drain regions with the insulating layer, the ROM of the present invention prevents currents from leaking between the substrate and the source/drain regions. Further, by performing program encoding implantation separately after channel transistor formation, enables a manufacturer to store ROMs having completed channel transistors, thus shortening the production time from customer order to delivery. Finally, the manufacturing method of ROM in accordance with the present invention may be used for manufacturing a ROM having a silicon on insulator (SOI) structure.
It will be apparent to those skilled in the art that various modifications and variations can be made to the ROM of the present invention without departing from the scope or spirit 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. | A read-only memory (ROM) and method for manufacturing a ROM having trench-type gate regions and source/drain regions, wherein the trench-type gate regions are provides in a substrate. The ROM further includes an insulating layer for isolating the substrate from the source/drain regions so to prevent current leakage between the source/drain regions and the substrate and to reduce area required by components of the ROM, thereby increasing component integration. The ROM also comprises a checkerboard conductive layer having a plurality of parallel source/drain regions a plurality of parallel channel regions connected to the plurality of parallel source/drain regions, wherein the plurality of parallel source/drain regions and the plurality of parallel channel regions cross each other at right angle, while the source/drain regions and the trench-type gate regions are approximately parallel to each other. | 7 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This patent application claims the benefit under 35 U.S.C. §119(e) of U.S. Provisional Application No. 60/708,407, filed Aug. 15, 2005, which application is incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates generally to torque converter clutches, more particularly, to a torque converter clutch for a constant slip application, and, more specifically, to a durable, high cooling efficiency torque converter clutch for a constant slip application.
BACKGROUND
[0003] Hydraulic torque converters, devices used to change the ratio of torque to speed between the input and output shafts of the converter, revolutionized the automotive and marine propulsion industries by providing hydraulic means to transfer energy from an engine to a drive mechanism, e.g., drive shaft or automatic transmission, while smoothing out engine power pulses. A torque converter includes three primary components, an impeller, sometimes referred to as a pump, directly connected to the engine's crankshaft, a turbine, similar in structure to the impeller, however the turbine is connected to the input shaft of the transmission, and a stator, located between the impeller and turbine, which redirects the flow of hydraulic fluid exiting from the turbine thereby providing additional rotational force to the pump. This additional rotational force results in torque multiplication. Thus, for example, when the impeller speed is high and the turbine speed is low, torque may be multiplied by a 2:1 or higher ratio, whereas when the impeller and turbine speeds are approximately the same, torque can be transferred at about a 1:1 ratio.
[0004] Although torque can be transferred at approximately a 1:1 ratio, there remains an amount of slippage between the impeller and turbine. Slippage results in lower fuel efficiency and therefore is less desirable. The push for increased fuel economy and gas mileage encouraged the development of torque converters having a clutch, i.e., a lock-up mechanism. When the speed of a vehicle having a torque converter clutch reaches a predetermined level, e.g., 40 miles per hour, hydraulic fluid in the stator shaft is pressurized, activating the clutch piston, which locks the torque converter output shaft to the converter housing, and thus connecting the engine output shaft to the transmission input shaft. The activated clutch piston, i.e., an engaged clutch, eliminates slippage, and thus improves fuel economy and gas mileage.
[0005] More recently, slipping clutches have been included in torque converter designs, as similar benefits to a locking system may be realized. Slipping clutches may be engaged sooner, i.e., at a lower engine speed or rotations per minute (RPM), as a result of the superior drivetrain isolation achieved with a slipping system. A result of the aforementioned non-locking system is that the clutch piston is constantly slipping along the housing cover. As is well-known, when two surfaces slip with respect to each other, frictional forces promote the generation of heat energy. An increase in temperature of the torque converter, and thus the hydraulic fluid within the converter, accelerates the degradation of both the fluid and the friction material used between the piston and the converter housing. Hence, since the introduction of torque converters having a slipping mechanism, the need to dissipate heat energy from the torque converter clutch has also existed.
[0006] Various methods and apparatus have been employed to minimize the increase in torque converter clutch temperature. For example, U.S. Pat. No. 4,423,803 (Malloy) teaches a torque converter clutch having a temperature regulator valve. Once hydraulic fluid in the apply chamber reaches a predetermined temperature, a bi-metallic valve opens, thereby permitting hydraulic fluid to flow between the apply chamber and the release chamber. Thus, the increased flow of fluid between the two chambers provides cooling for the clutch mechanism.
[0007] Additionally, grooves within the friction material or converter housing have been included to permit fluid flow from the apply chamber to the release chamber. Similar to the aforementioned bimetallic valve arrangement, heat is transferred away from the clutch region. However, both groove configurations have drawbacks. When grooves are formed within the friction material, they must be sufficiently deep to permit flow over an extended period of time, as the material wears away with use. Additionally, friction materials are typically poor conductors of heat energy and therefore can not be used to effectively remove heat from the torque converter clutch. Lastly, grooves in the cover have the tendency to prematurely wear the friction material, i.e., a cheese grater effect.
[0008] As can be derived from the variety of devices and methods directed at removing heat from the torque converter clutch, many means have been contemplated to accomplish the desired end, i.e., lengthy fluid and part life, without sacrificing the higher fuel efficiency and gas mileage afforded by a lock-up mechanism. Heretofore, tradeoffs between fluid and/or part life and fuel efficiency were required. Thus, there has been a longfelt need for a torque converter clutch having high cooling efficiency and durability.
BRIEF SUMMARY OF THE INVENTION
[0009] The present invention broadly includes a torque converter clutch having a cover and a friction plate, wherein the friction plate is secured to the cover, and at least one channel, having a channel input and a channel output, located between the friction plate and the cover. In one embodiment the friction plate is welded to the cover, while in another embodiment the friction plate and cover are secured by brazing, and in yet another embodiment the friction plate and cover are secured by an adhesive material. The at least one channel is operatively arranged to allow hydraulic fluid to flow between the cover and friction plate, thereby drawing heat away from the torque converter clutch. In yet another embodiment, the at least one channel includes a one-way valve operatively arranged to permit hydraulic fluid to flow out of the channel through the channel output, while preventing fluid from flowing into the channel output.
[0010] A general object of the invention is to enable efficient transfer of heat away from a torque converter clutch.
[0011] Another object of the invention is to extend the useful life of a torque converter clutch by preventing the deterioration of friction material and/or hydraulic fluid.
[0012] These and other objects, features, and advantages of the present invention will become readily apparent to one having ordinary skill in the art upon reading the detailed description of the invention in view of the drawings and appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The nature and mode of operation of the present invention will now be more fully described in the following detailed description of the invention taken with the accompanying drawing figures, in which:
[0014] FIG. 1 is a perspective view of a torque converter;
[0015] FIG. 2 is a cross-sectional view of the torque converter shown in FIG. 1 , taken generally along line 2 - 2 of FIG. 1 ;
[0016] FIG. 3A is a front elevational view of a cover and friction plate of the present invention having internally located channels with channel inputs proximate other channel inputs;
[0017] FIG. 3B is a front elevational view of a cover and friction plate of the present invention having internally located channels with channel inputs proximate channel outputs;
[0018] FIG. 4 is a perspective view of the friction plate of the present invention showing a plurality of channels;
[0019] FIG. 5 is a cross-sectional view of the friction plate shown in FIG. 4 , taken generally along line 5 - 5 of FIG. 4 ; and,
[0020] FIG. 6 is an enlarged cross-sectional view of an embodiment of the cover and friction plate of the present invention shown in the encircled region 6 of FIG. 2 having a one-way valve operatively arranged at a channel output.
DETAILED DESCRIPTION OF THE INVENTION
[0021] At the outset, it should be appreciated that like drawing numbers on different drawing views identify identical, or functionally similar, structural elements of the invention. While the present invention is described with respect to what is presently considered to be the preferred embodiment, it is to be understood that the invention as claimed is not limited to the preferred embodiment.
[0022] Furthermore, it is understood that this invention is not limited to the particular methodology, materials and modifications described and as such may, of course, vary. It is also understood that the terminology used herein is for the purpose of describing particular embodiments only, and is not intended to limit the scope of the present invention.
[0023] Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood to one of ordinary skill in the art to which this invention belongs. Although any methods, devices or materials similar or equivalent to those described herein can be used in the practice or testing of the invention, the preferred methods, devices, and materials are now described.
[0024] Adverting now to the figures, FIG. 1 shows a perspective view of torque converter 10 . Torque converter 10 includes first housing cover 12 , second housing cover 14 , and housing hub 16 . In a preferred embodiment, torque converter 10 is operatively arranged to transfer torque between an engine and a transmission, as described supra. Thus, converter 10 is positioned so that first housing cover 12 may be coupled to a flywheel of the engine (not shown), stator shaft 32 (see FIG. 2 ) may be coupled to a fixed transmission mount (not shown), and transmission input shaft 34 (see FIG. 2 ) may be engaged with turbine hub 35 (see FIG. 2 ). Because converter 10 is fixedly secured to the engine flywheel, converter 10 rotates as the flywheel rotates. The result of such rotation is described above, and further described infra. As the engine and transmission are not particularly germane to this invention, they are not discussed in detail.
[0025] FIG. 2 shows a cross-sectional view of torque converter 10 , taken generally along line 2 - 2 of FIG. 1 . Converter 10 generally includes first and second housing covers 12 and 14 , respectively, wherein pump 18 , stator 20 , turbine 22 , piston 24 which includes friction material 26 , friction plate 28 , damper 30 , stator shaft 32 , transmission input shaft 34 , and turbine hub 35 are located. Hydraulic fluid (shown as arrows) enters converter 10 through first cavity 36 , the volume created between the inner wall of stator shaft 32 and the outer wall of transmission input shaft 34 , and subsequently pressurizes the fluid volume contained within piston 24 and first and second housing covers 12 and 14 , respectively, i.e., apply cavity 40 . Although fluid entry and pressurization, in this embodiment, is described as occurring through first cavity 36 , one of ordinary skill in the art recognizes that such entry and pressurization may also occur in the volume between housing hub 16 and stator shaft 32 . Due to the rotation of converter 10 , the hydraulic fluid is transferred via centrifugal force from pump 18 to turbine 22 , whereby engine torque is also transmitted to turbine 22 . As a result of the shape of turbine 22 , the hydraulic fluid is then returned to pump 18 , through stator 20 . Stator 20 alters the flow direction of the hydraulic fluid thereby improving the torque multiplication of converter 10 .
[0026] As described supra, torque converters may include lock-up mechanisms to provide improved efficiency and gas mileage. In the embodiment shown in FIG. 2 , converter 10 includes friction plate 28 fixedly secured to inner surface 38 of first housing cover 12 . In a preferred embodiment friction plate 28 is welded to inner surface 38 , however as one of ordinary skill in the art appreciates, other means of securing are possible, e.g., brazing and adhesives, and such other means are within the metes and bounds of the invention as claimed. Piston 24 including friction material 26 comprise the lock-up mechanism of converter 10 and are fixedly secured to damper 30 . Damper 30 is operatively arranged to reduce vibration conducted from the engine to the transmission (not shown).
[0027] Throughout operation, pressurized hydraulic fluid fills apply and release cavities 40 and 42 , respectively. At initial startup or under conditions when it is inappropriate to lock turbine shaft 34 to first housing cover 12 , the lock-up mechanism is not engaged. Therefore, hydraulic fluid pressure in apply and release cavities 40 and 42 , respectively, is typically low, e.g., 30 pounds per square inch, and approximately equal. As torque converter 10 and turbine shaft 34 approach a predetermined rotational rate with respect to each other, and the vehicle having such torque converter approaches a predetermined velocity, the hydraulic fluid pressure in apply cavity 40 is increased, e.g., 150 pounds per square inch, whereby piston 24 and friction material 26 are releasably engaged with friction plate 28 . Under the aforementioned lock-up condition, and more specifically due to frictional forces between friction plate 28 and friction material 26 , the vehicle engine is directly connected to the transmission and thus the vehicle's efficiency and gas mileage are improved. As converter 10 is brought under conditions that are not conducive for lock-up, e.g., the vehicle begins to slow in velocity, hydraulic fluid pressure in apply cavity 40 is reduced, and subsequently the constant pressure contained within release cavity 42 , being sufficient to overcome the reduced pressure in apply cavity 40 , causes friction material 26 to release from friction plate 28 .
[0028] Typically, while the lock-up mechanism is engaged, no hydraulic fluid is permitted to flow from apply cavity 40 to release cavity 42 . Hence, when converter 10 is under slipping conditions, heat energy may build up within the hydraulic fluid in apply cavity 40 , thereby promoting the aforementioned fluid degradation. Thus, in this embodiment, friction plate 28 having channel input 44 , channel 46 and channel output 48 (see FIG. 6 ), permits the flow of hydraulic fluid from apply cavity 40 to release cavity 42 , thereby removing heat energy from friction plate 28 via the hydraulic fluid. As friction plate 28 , in a preferred embodiment, is constructed from metal material, and metal being an efficient conductor of heat, the heat energy generated between friction plate 28 and friction material 26 may be substantially removed from this area by flowing hydraulic fluid through channel 46 . Upon exiting channel 46 through channel output 48 , the fluid enters release cavity 42 , and subsequently exits converter 10 through second cavity 50 , a bore located along the central axis of turbine shaft 34 . After the hydraulic fluid exits converter 10 , it may be cooled and then reintroduced through first cavity 36 as described supra.
[0029] FIG. 3A shows a front elevational view of cover 12 and friction plate 28 having channels 46 with channel inputs 44 and channel outputs 48 . In this embodiment, friction plate 28 is fixedly secured to cover 12 by continuous weld 57 . As continuous weld 57 seals the circumference of friction plate 28 , entrance of hydraulic fluid into channel 46 is limited by channel input 44 . Furthermore, in this embodiment, channel inputs 44 are operatively arranged so that each input 44 is proximate another input 44 , and all inputs 44 are located adjacent the outer radius of friction plate 28 , i.e., proximate continuous weld 57 . Additionally, as maintaining the tolerances of depth and width of channels 46 may be difficult during manufacture, in this embodiment the rate of hydraulic fluid flow within channel 46 is controlled by the diameter of channel input 44 . Although the manufacturing reproducibility of the diameter of channel input 44 is more easily maintained, and thus is typically the means of controlling rate of fluid flow, it is within the scope of this invention to control the size and shape of channel 46 or the diameter of channel output 48 , and thereby fix the rate of fluid flow through channel 46 . It will also be appreciated by one of ordinary skill in the art that although channels 46 are depicted as zig-zag patterns, any pattern connecting channel input 44 with channel output 48 is possible, e.g., straight line or complex lattice, and such variations are within the scope of the invention.
[0030] FIG. 3B shows a front elevational view of another embodiment of cover 12 and friction plate 28 having channels 47 with channel inputs 45 and channel outputs 49 . In this embodiment, channels 47 comprise a honeycomb pattern, wherein hydraulic fluid is transferred from inputs 45 to outputs 49 . Thus, the rate of hydraulic fluid flow through channel 47 is controlled by the diameter of outputs 49 . Contrary to the embodiment shown in FIG. 3A , in this embodiment friction plate 28 is fixedly secured to cover 12 by spot-welds 56 and continuous weld 57 about the outer and inner circumferences of plate 28 , respectively. As described supra, other configurations of channel construction, e.g., straight lines or zig-zag patterns, as well as controlling the rate of fluid flow by maintaining the tolerances of channel 47 or the size of inputs 45 , are within the scope of the invention as claimed.
[0031] FIG. 4 is a perspective view of friction plate 28 showing a plurality of channels 46 according to FIG. 3A . In this embodiment, channels 46 are formed within surface 52 of friction plate 28 . Subsequently, plate 28 is fixedly secured to first housing cover 12 , as described above, having surface 52 of friction plate 28 in contact with surface 38 of first housing cover 12 . Although in this embodiment channels 46 are formed in surface 52 , one of ordinary skill in the art will appreciate that channels 46 may also be formed within first housing cover 12 . Thus, channel inputs 44 must merely be aligned to the channels formed in first housing cover 12 , prior to fixedly securing friction plate 28 to cover 12 with continuous weld 57 (see FIG. 3A ).
[0032] FIG. 5 is a cross-sectional view of friction plate 28 , taken generally along line 5 - 5 of FIG. 4 . Although in the embodiments disclosed, the rate of fluid flow within channel 46 is primarily controlled by the diameter of channel input 44 , in part the rate of flow may be controlled by the width and depth of channel 46 . Thus, by forming a wider and/or deeper channel 46 , the resistance to fluid flow within channel 46 may be decreased and therefore less pressure within apply cavity 40 (see FIG. 2 ) is required to drive the fluid through channel 46 to release cavity 42 .
[0033] FIG. 6 is an enlarged cross-sectional view of an embodiment of cover 12 and friction plate 28 of the present invention shown in the encircled region 6 of FIG. 2 , and also shown in the front elevational view of FIG. 3B . This embodiment further includes one-way valve 54 operatively arranged at channel output 49 . As described supra, friction plate 28 may be fixed secured to first housing cover 12 by spot-welds 56 and continuous weld 57 , whereby channels 47 are sealed, thus limiting fluid entrance and exit to channel inputs 45 and channel outputs 49 , respectively. In this embodiment, one-way valve 54 precludes fluid flowing from release cavity 42 to apply cavity 40 . Hence, when one-way valve 54 is incorporated in the instant invention, and the lock-up mechanism is engaged, hydraulic fluid may only flow from apply cavity 40 to release cavity 42 , and flow is prevented in the opposite direction. Although not depicted, the instant invention may also be used without one-way valve 54 , and as such, the pressure differential between apply and release chambers 40 and 42 , respectively, controls the direction of flow within channels 47 .
[0034] Thus, it is seen that the objects of the present invention are efficiently obtained, although modifications and changes to the invention should be readily apparent to those having ordinary skill in the art, which modifications are intended to be within the spirit and scope of the invention as claimed. It also is understood that the foregoing description is illustrative of the present invention and should not be considered as limiting. Therefore, other embodiments of the present invention are possible without departing from the spirit and scope of the present invention. | A torque converter clutch for a constant slip application including a cover, a friction plate secured to the cover, and at least one channel between the cover and the friction plate. In another embodiment, the torque converter clutch may further include a one-way valve operatively arranged to permit a fluid to flow out of a channel, while preventing the fluid from flowing in through the channel. | 5 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application claims priority from German Patent Application Nos. 102 42 390.3 and 103 29 835.5, which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
The invention relates to an apparatus at a draw frame or other textile machine having a drawing mechanism for the doubling and drafting of fibre slivers.
Certain forms of draw frame have a drawing mechanism frame for accommodating the drawing mechanism, which has at least two pairs of rollers each comprising an upper roller and a lower roller, and means for adjusting the spacing of at least one of the lower rollers in relation to another lower roller, in each case having a mounting device for accommodating the lower roller, and lower rollers are arranged to be driven by at least one drive element endlessly revolving around pulley wheels and wherein each lower roller has a roller-driving pulley wheel.
In a known apparatus (DE-OS 20 44 996), the mountings of the intake and middle lower rollers are displaceable on the frame of the machine so that the extent of the drawing zone can be matched to the particular fibre staple. A tensioning pulley wheel, which is displaceable in a guideway in the frame of the machine, allows the length of the toothed belt to be modified in accordance with the changed spacing between the axes of the middle roller and a guide pulley wheel, brought about by displacement of the intake roller. The middle roller is driven by a further toothed belt. The latter toothed belt is tensioned by a tensioning pulley wheel which is fastened to the machine frame and which can pivot about one axis; as a result, it can also be matched to changed spacings between the axes of the intake roller and middle roller. It is disadvantageous that displacing devices for displacement of the intake roller and the middle roller and additional tensioning devices for re-tensioning of the toothed belts after the displacement operations are necessary, requiring a considerable outlay in terms of construction. In addition, it is disadvantageous that a number of work steps are required for the displacement operations and the subsequent re-tensioning operations. The belt tension is destroyed by the displacement process. Where the displacement is carried out manually, spacers are inserted between the mountings, the mountings being pushed against the spacers so that, in this case too, the amount of set-up work is considerable. Finally, the displacement and re-tensioning operations result in a doubling of potential error sources when setting the spacings and belt tensions.
It is an aim of the invention accordingly to provide an apparatus of the kind described at the beginning that avoids or mitigates the disadvantages mentioned and that especially is of simple construction and allows a considerable reduction in the work and time required for adjustment of the slider(s) and, accordingly, of the extent(s) of the drawing zone(s), without re-tensioning the drive belt after the adjustment.
SUMMARY OF THE INVENTION
The invention provides a drawing mechanism having a drawing mechanism frame, at least two pairs of rollers each comprising an upper roller and a lower roller and having a mounting device for accommodating the lower roller, means for adjusting the spacing of at least one of the lower rollers in relation to another lower roller, and at least one drive device comprising a drive element endlessly revolving around pulley wheels, wherein said pulley wheels comprise a guide pulley wheel provided on a said mounting device and a roller-driving pulley wheel for driving the lower roller accommodated by that mounting device, said roller-driving pulley wheel and said guide pulley wheel acting one after another on opposed sides of the drive element.
The measures according to the invention make it possible, by simple means, for the mountings and, as a result, the extents of the drawing zones (nip line spacings) to be adjusted in a short time. For the purpose of adjusting the extents of the drawing zones, elegant use is made of existing structural elements necessarily present in the drawing mechanism, namely a roller-driving pulley wheel and the drive belt. Separate apparatuses for adjustment are not required. As a result of the fact that the drive belt is in tension before, during and after adjustment, further apparatuses for re-tensioning the drive belt after the adjustment are not required, which allows the extents of the drawing zones of the drawing mechanism to be changed in a short time by means that are especially simple in terms of construction.
Advantageously, the drive device can be used for adjusting the position of the mounting device of said lower roller, whereby said adjustment of said spacing is effected. Advantageously, at least one pulley wheel and the tensioned drive element are used for adjusting the mounting device. Advantageously, the drive element is stationary and the pulley wheel is rotated. Advantageously, the pulley wheel is stationary and the drive element is moved. Advantageously, the rotation of the pulley wheel or the movement of the drive element is converted into the adjusting movement of the slider. Advantageously, at least one guide pulley wheel is attached to each slider (mounting); and the roller-driving pulley wheel or guide pulley wheel(s) act, in each case one after the other, on both sides of the tensioned drive element. Advantageously, the rotation of the pulley wheel or the movement of the drive element is accomplished manually. Advantageously, the slider is linearly displaceable.
Advantageously, the drive element is a toothed belt. Advantageously, an endless flexible toothed belt is present. Advantageously, the pulley wheels comprise toothed belt wheels. Advantageously, the pulley wheels comprise guide pulley wheels. Advantageously, at least one driving pulley wheel is provided. Advantageously, driven pulley wheels are present. Advantageously, the drive element loops around the pulley wheels. Advantageously, the drive element and the pulley wheel are in engagement with one another. Advantageously, the pulley wheel for adjustment of a slider is the drive pulley wheel of a lower roller (roller-driving pulley wheel). Advantageously, the slider is displaceable during adjustment. Advantageously, the slider is arranged to be stopped. Advantageously, the stopping arrangement is releasable. Advantageously, a display device for the position of the slider is present.
Advantageously, a drive motor is used for rotation of the pulley wheel. Advantageously, a drive motor is used for movement of the drive element. Advantageously, the drive motor is used for the lower rollers. Advantageously, a separate drive motor is used. Advantageously, belt shortening or belt lengthening is arranged to be automatically evened out during adjustment. Advantageously, the evening-out of belt length is carried out at a slider by two guide pulley wheels.
Advantageously, the lower rollers are arranged to be adjusted singly and independently of one another. Preferably, a roller-driving pulley wheel and a guide pulley wheel are attached to the slider of the intake roller and a roller-driving pulley wheel and a guide pulley wheel are attached to the slider of the middle roller. Advantageously, the drive element runs around the pulley wheels at the slider of the intake roller and around the pulley wheels at the slider of the middle roller in a mirror-reflected arrangement. Advantageously, the drive element is in tension before, during and after the displacement. Advantageously, the drive motor is in communication with an electronic control and regulation device. Advantageously, a measuring element is connected to the control and regulation device. Advantageously, the measuring element is capable of registering fibre-related and/or machinery-related measurement variables. Advantageously, adjustment of the slider is carried out when the drawing mechanism is in operation. Advantageously, adjustment of the slider is carried out when the drawing mechanism is not in operation. Advantageously, adjustment of the slider is carried out during can-changing. Advantageously, the draw frame is self-adjusting. Advantageously, adjustment of the slider is carried out by inputting adjustment variables. Advantageously, the adjustment variables can be input manually. Advantageously, a memory for adjustment variables is connected to the control and regulation device. Advantageously, the slider for the intake roller and the slider for the middle roller are arranged to be connected by a rigid connecting element. Advantageously, the connecting element is releasably connected. The spacing of the pairs of rollers in relation to one another may be adjustable without fibre material. The spacing of the pairs of rollers in relation to one another may be adjustable with fibre material. Advantageously, the extent of the preliminary draft zone can be adjusted. Advantageously, the extent of the main draft zone can be adjusted. Advantageously, the extent of the preliminary draft zone and the extent of the main draft zone can be adjusted. Advantageously, each lower roller has its own associated drive motor. Advantageously, the intake and middle lower rollers are arranged to be driven by one drive motor. Advantageously, a brake, stopping arrangement or the like is associated with the stationary pulley wheel. The brake, stopping arrangement or the like may be mechanical, electrical or electromagnetic. Advantageously, the drive motor is a self-braking motor. Advantageously, the drive motor drives a further drive train, which has a free-wheel arrangement or the like.
Advantageously, the mounting device consists of the mounting and the slider. The mounting and the slider may be fastened to one another, for example by bolts. The mounting and the slider may be of integral construction.
The invention also provides an apparatus at a draw frame having a drawing mechanism for the doubling and drafting of fibre slivers, having a drawing mechanism frame for accommodating the drawing mechanism, which has at least two pairs of rollers each comprising an upper roller and a lower roller, having means for adjusting the spacing of at least one of the lower rollers in relation to another lower roller, in each case having a mounting device for accommodating the lower roller, wherein lower rollers are arranged to be driven by at least one drive element endlessly revolving around pulley wheels, characterised in that at least one guide pulley wheel is attached to each mounting device; and the roller-driving pulley wheel or guide pulley wheel act, in each case one after the other, on both sides of the tensioned drive element.
Moreover, the invention provides a draw frame comprising a drawing mechanism as defined above.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic side view of an autoleveller draw frame for use with an apparatus according to the invention together with a general circuit diagram;
FIG. 2 is a perspective view of a side of the draw frame showing the displaceable mounting of the intake and middle lower rollers;
FIGS. 3 a and 3 b show the drive for the intake and middle lower rollers for the draw frame according to FIG. 1, in a side view (FIG. 3 a ) and plan view (FIG. 3 b );
FIG. 3 c is a partial side view of a drive belt;
FIGS. 4 a to 4 d show, in diagrammatic form, the sequential procedure for shortening of the preliminary and main draft zones;
FIGS. 5 a and 5 b show the intake and middle lower rollers before displacement (FIG. 5 a ) and after displacement (FIG. 5 b );
FIGS. 6 a and 6 b show, in diagrammatic form, an electro-magnetic braking apparatus for a toothed belt wheel;
FIG. 7 shows a locking device for a slider;
FIG. 8 shows a connection element (bridge) for connecting two sliders;
FIG. 9 is a partial side view of an embodiment comprising a drawing mechanism having three roller combinations, each having its own drive motor;
FIG. 10 is a side view of a drawing mechanism with input devices for manual and/or memory-assisted input of adjustment values for changing the nip line spacings in the drawing mechanism; and
FIG. 11 is a front view of a roller pair with an upper roller lifted off from a lower roller.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In accordance with FIG. 1, a draw frame 1 , for example a draw frame known as an HSR draw frame (trade mark) made by Trüitzschler GmbH & Co. KG, has a drawing mechanism 2 , upstream of which is an intake 3 of the drawing mechanism and downstream of which is an exit 4 from the drawing mechanism. The fibre slivers 5 , coming from cans (not shown), enter the sliver guide 6 and, drawn by the draw-off rollers 7 , 8 , are transported past the measuring element 9 . The drawing mechanism 2 is designed as a 4-over-3 drawing mechanism, that is to say it consists of three lower rollers I, II, III (I delivery lower roller, II middle lower roller, III intake lower roller) and four upper rollers 11 , 12 , 13 , 14 . Drafting of the fibre sliver combination 5 ′ from a plurality of fibre slivers 5 is carried out in the drawing mechanism 2 . Drafting is composed of preliminary drafting and main drafting. The roller pairs 14 /III and 13 /II form the preliminary draft zone and the roller pairs 13 /II and 11 , 12 /I form the main draft zone.
The attenuated fibre slivers 5 reach a web guide 10 in the exit 4 from the drawing mechanism and, by means of the draw-off rollers 15 , 16 , are drawn through a sliver funnel 17 , in which they are combined to form one fibre sliver 18 , which is then deposited in cans. Reference letter A denotes the work direction.
The draw-off rollers 7 , 8 , the intake lower roller III and the middle lower roller II, which are connected to one another mechanically, for example by toothed belts, are driven by the control motor 19 , it being possible, in the process, for a desired value to be specified. (The associated upper rollers 14 and 13 , respectively, revolve by virtue of the motion of the lower rollers.) The delivery lower roller I and the draw-off rollers 15 , 16 are driven by the main motor 20 . The control motor 19 and the main motor 20 each have their own controller 21 and 22 , respectively. Control (speed-of-rotation control) is carried out in each case by means of a closed control loop, a tachogenerator 23 being associated with the control motor 19 and a tachogenerator 24 being associated with the main motor 20 . At the intake 3 of the drawing mechanism, a variable proportional to the weight of the fibre slivers 5 fed in, for example their cross-section, is measured by an intake measuring element 9 known, for example, from DE-A-44 04 326. At the exit 4 from the drawing mechanism, the cross-section of the delivered fibre sliver 18 is ascertained by an exit measuring element 25 associated with the sliver funnel 17 and known, for example, from DE-A-195 37 983. A central computer unit 26 (control and regulation device), for example a microcomputer with a microprocessor, sends a setting for the desired value for the control motor 19 to the controller 21 . The measurement values of the two measuring elements 9 and 25 are sent to the central computer unit 26 during the drawing process. The desired value for the control motor 19 is determined in the central computer unit 26 from the measurement values of the intake measuring element 9 and from the desired value for the cross-section of the delivered fibre sliver 18 . The measurement values of the exit measuring element 25 are used for monitoring of the delivered fibre sliver 18 (delivered sliver monitoring). By means of this control system, it is possible for variations in the cross-section of the fibre slivers 5 fed in to be compensated, and for the fibre sliver to be made more uniform, by appropriately regulating the drafting process. Reference numeral 27 denotes a display monitor, 28 an interface, 29 an input device, 30 a pressure rod and 31 a memory.
With reference to FIG. 2, each of lower rollers II, III has an associated mounting device comprising a respective mounting 33 a , 34 a. The trunnions Ia, IIa, IIIa (see FIG. 3 b ) of the lower rollers I, II and III are mounted so as to be capable of rotation in mountings 32 a, 33 a , 34 a ( 32 b, 33 b , 34 b are located on the other side of the drawing mechanism and are not shown). The mountings 33 a and 34 a are bolted onto sliders 35 a and 36 a, respectively, which are displaceable in the direction of the arrows C, D and E, F, respectively, along a bar 37 a. The two ends of the bar 37 a are fixedly mounted in mounting blocks 38 ′ ( 38 ″ not shown), which are attached to the frame 39 of the machine.
Displacement of the sliders 35 a, 35 b; 36 a, 36 b at the same time causes the mountings 33 a , 33 b ; 34 a, 34 b and, as a result, the lower rollers II and III, respectively, to be displaced and moved in directions C, D and E, F, respectively. The associated upper rollers 13 and 14 are correspondingly moved (in a manner not shown) in directions C, D and E, F, respectively. By that means, the nip line spacings between the roller combinations are modified and set.
Locking of the sliders 35 a, 35 b; 36 a, 36 b is accomplished by means of a catch device, stopping device or he like, one suitable form of stopping device being shown n FIG. 7 .
Referring to FIG. 3 a , the lower rollers II and III are driven from the right-hand side of the draw frame, seen in the direction of material flow A, by means of a common loop mechanism in the form of toothed belt wheels 40 , 41 and a toothed belt 47 . The different speeds of rotation of the lower rollers II and III are achieved by means of change-gearwheels at the drive trunnions IIa, IIIa provided with different numbers of teeth. The toothed belt 47 runs in direction B (that is to say contrary to the work direction) onto the control drive, which is in the form of a servo motor 19 . The lower roller I is driven from the left-hand side of the machine by means of a loop mechanism in the form of toothed belt wheels and a toothed belt 47 ′. For that purpose, the toothed belt 47 ′ runs on the left-hand side from the toothed belt disc 40 ′ at the lower roller I in direction G onto the servo motor 20 .
In operation, that is to say when the fibre slivers are running in direction A, the toothed belt 47 moves in direction G. Starting from the toothed belt wheel 47 arranged on the drive motor 19 , the toothed belt 47 runs successively over a toothed belt wheel 45 , a smooth guide pulley wheel 46 , the toothed belt wheel 40 (roller-driving pulley wheel for the lower roller III), the toothed belt wheel 41 (roller-driving pulley wheel for the lower roller II), a smooth guide pulley wheel 42 and a toothed belt wheel 43 . As shown in FIG. 3 c, the belt 47 has a toothed side 47 a and a smooth side 47 b. By means of its teeth, the toothed belt 47 , by means of teeth 47 a (FIG. 3 c ) is in positive engagement with the toothed belt wheels 40 , 41 , 43 , 44 , and 45 . The smooth side 47 b (reverse) (FIG. 3 c ) of the toothed belt 47 , opposite the toothed side, is in contact and in engagement with the smooth guide pulley wheels 46 and 42 . The toothed belt 47 loops around all the pulley wheels 40 to 46 . In operation (when the fibre slivers are running in direction A during drafting), the toothed belt wheels 40 , 41 , 43 , 44 , and 45 rotate clockwise and the guide pulley wheels 42 and 46 rotate anti-clockwise.
The toothed belt wheels 40 , 41 are associated with the mountings 34 a and 33 a , respectively, whereas the guide pulley wheels 42 , 46 are attached to the sliders 35 a and 36 a, respectively, in a manner allowing rotation. Because 20 of the rigid attachment between the mounting 34 a and the slider 36 a and between the mounting 33 a and the slider 35 a (for example, by means of bolts), there are associated with the lower rollers II and III, in each case, one toothed belt wheel 40 and 41 , respectively, and one guide pulley wheel 46 and 42 , respectively. The toothed belt 47 runs around the pulley wheels 40 , 46 , on the one hand, and around the pulley wheels 41 , 42 , on the other hand, in a mirror-reflection arrangement (see FIG. 3 b ).
The zone between the pairs of rollers 13 /II and 14 /III is designated VV (preliminary drafting) and the zone between the pairs of rollers 12 /I and 13 /II is designated HV (main drafting) (see FIG. 4 a ). When, in accordance with FIG. 3 a , the nip line spacing between the roller pairs 14 /III and 13 /II is to be increased, at least one pair of rollers must be moved away from the respective other pair of rollers. For that purpose the slider 35 a may be displaced towards the right, which may be accomplished in two ways:
a) The slider 35 a is unlocked. A pulley wheel, for example the toothed belt wheel 44 , is stopped so that there is no possibility of rotation. Stopping may be accomplished, for example, by mechanical or electromagnetic means. As a result the toothed belt 47 is stationary and cannot be moved. The toothed belt wheel 41 is then rotated anti-clockwise, for example manually using a crank or the like, whereupon the guide pulley wheel 42 likewise rotates, clockwise, as a matter of necessity. In the process, the rotary movement of the toothed belt wheel 41 is converted into a longitudinal movement of the slider 35 a in direction C, the toothed belt wheel 41 and the guide pulley wheel 42 winding along opposite sides of the stationary toothed belt 47 , thereby “shortening”, as it were, the toothed belt 47 at one pulley wheel and “lengthening” it at the other pulley wheel. The length of belt required during that “winding along” at the toothed belt wheel 41 is made available at the guide pulley wheel 42 . The lower roller II is thereby displaced in direction C by means of the slider 35 a and the mounting 33 a.
b) The slider 35 a is unlocked. The toothed belt wheel 41 is stopped so that there is no possibility of rotation. As a result the guide pulley wheel 42 is also stopped of necessity. Then, clockwise rotation is brought about by means of the drive motor 19 . The toothed belt 47 moves in direction G, likewise “shortening” the belt 47 at one pulley wheel and “lengthening” it at the other pulley wheel. The length of belt actually required between the toothed belt wheels 40 and 41 is made available between the toothed belt wheels 43 and pulley wheel 42 . The rotary movement of the toothed belt wheel 44 and the movement of the toothed belt 47 is thereby converted into a longitudinal movement of the slider 35 a in direction C. The lower roller II, mounted in the mounting 33 a (which is rigidly connected to the slider 35 a ), is likewise moved in direction C as a result.
In practice, it is often the case that, in accordance with FIGS. 4 a to 4 d, first the preliminary draft zone VV is modified and then the main draft zone HV. In the case of shortening of the draft zones VV and HV, the slider 36 a is displaced in the direction of the arrow E from the position according to FIG. 4 a into the position according to FIG. 4 b. As a result, the nip line spacing in the preliminary draft zone VV is reduced from “a” to “a”. Then, in accordance with FIG. 4 c, the sliders 36 a and 35 a are rigidly connected to one another by means of a bridge 50 . Finally, the rigidly coupled sliders 36 a and 35 a are moved, in accordance with FIG. 4 d, in the direction of the arrows E and C, from the position shown in FIG. 4 c into the position shown in FIG. 4 d. As a result, the nip line spacing in the main draft zone HV is shortened from “b” to “b′”.—A corresponding procedure is used in the case of lengthening the preliminary and main draft zones, that is to say the coupled sliders 35 a and 36 a are displaced in the direction of the arrows F and D (see FIG. 2 ), as a result of which the main draft zone HV is lengthened. Then, the sliders 35 a and 36 a are uncoupled from the bridge 50 . Finally, the slider 36 a is moved in the direction of the arrow F (see FIG. 2 ), as a result of which the preliminary draft zone VV is lengthened.
With regard to the fibre slivers 5 in the drawing mechanism 2 , it should be noted that, in the case of shortening of the draft zones VV and HV, a small amount of stretching, in direction B, of the fibre slivers 5 IV upstream of the pair of rollers 14 /III can occur on displacement in accordance with FIGS. 4 a, 4 b, but because of the length (about 1.5 m) of the spacing between the transport rollers 7 , 8 and the pair of rollers 14 /III this is without significance. In the case of shortening, a sagging loop does not form in the preliminary draft zone VV because in the case of displacement referring to the pairs of rollers 14 /III and 13 /II either one or both pairs of rollers are rotatable because the drives to both pairs of rollers are coupled by way of the toothed belt 47 . In contrast, in the case of shortening of the main draft zone HV, a sagging loop is formed in fibre slivers 5 ″, which is drawn out or drawn straight by rotation of the pair of rollers 12 /I in the work direction A by means of the main motor 20 .—In the case of lengthening of the draft zones VV and HV, the pair of rollers 12 /I is, in a first step, rotated backwards in direction B, whereupon a sagging loop is intentionally formed in the fibre slivers 5 ″. When the main draft zone HV is subsequently lengthened by displacement of the coupled sliders 35 a and 36 a in direction D and F, the artificially formed loop is, in the process, once again drawn out or drawn straight. Finally, after uncoupling of the bridge 50 , the slider 36 a is displaced in direction F. As a result of the above-mentioned coupling of the drives to the intake and middle lower roller pairs by means of the toothed belt 47 , the length of the fibre slivers 5 ′ in the preliminary draft zone VV remains unaffected. Possible slight longitudinal compression of the fibre slivers 5 IV upstream of the pair of rollers 14 /III is, in respect of the drafting and the constitution of the fibre slivers 5 IV , without significance.
FIGS. 5 a, 5 b show a suitable construction for bringing about the displacement of the sliders 36 a and 35 a. The nip line spacing in the preliminary draft zone VV is lengthened from “a” (FIG. 5 a ) to “a” (FIG. 5 b ). The sliders 36 a and 35 a are displaced one after the other according to the arrows E and C, respectively. Displacement is accomplished by stopping the toothed belt wheel 40 or fixing it with a holding brake or the like and then actuating the drive motor 19 , whereupon the toothed belt 47 moves. In continuation thereof, the sliders 36 a and 35 a are displaced in accordance with FIGS. 4 a, 4 b and, subsequently, FIGS. 4 c, 4 d.
In FIG. 6 a there is shown an electromagnetic holding brake for braking the toothed belt wheel 44 . The brake has a rod-shaped iron core 53 surrounded by a plunger coil 54 . Mounted on one end face of the iron core 53 is a brake shoe 55 , for example made of plastics material or the like. The iron core 53 is displaceable in the direction of the arrows M, N. When current flows through the plunger coil 54 , the iron core 53 is moved in direction M, in accordance with FIG. 6 b, so that the brake shoe 55 is pressed against the smooth cylindrical surface of the shaft 44 a of the toothed belt wheel 44 . As a result, the toothed belt wheel 44 is fixed (stopped) so that it cannot rotate, for as long as voltage is applied to the plunger coil 54 .
In FIG. 7 there is shown a stopping device for slider 36 a and corresponding lower roller III. A pneumatic cylinder 60 having a piston rod 61 is attached to the slider 36 a. When subjected to pressure from the pneumatic cylinder 60 , the piston rod 61 is moved out in the direction of the arrow P and comes to rest, with a high degree of contact pressure, against the machine frame 61 . The slider 36 a is fixed (stopped) so that it cannot be displaced with respect to the bar 37 a, for as long as compressed air is applied to the pneumatic cylinder 60 . Lower roller II may be provided with an analogous arrangement.
In accordance with FIG. 8, there is provided, as the bridge 50 between the sliders 35 a and 36 a, a flat piece of metal (plate), which is fastened in the region of one of its ends 50 a to the slider 36 a, for example using bolts. In its region 50 b facing the slider 35 a, the flat piece of metal has an elongate hole 50 c, through which a bolt 62 can engage in a threaded hole (not shown) in the slider 35 a. By means of this bridge 50 , the sliders 35 a and 36 a can be rigidly connected to one another, releasably, at different spacings with respect to one another.
In accordance with FIG. 9, in contrast to FIG. 1, each lower roller I, II and III is driven by its own drive motor 20 , 52 and 19 , respectively, as shown, for example, in DE-OS 38 01 880. The motor 20 drives the toothed belt wheel 55 of the lower roller I by way of the toothed belt 56 ; the motor 52 drives the toothed belt wheel 41 of the lower roller II by way of the toothed belt 57 ; and the motor 19 drives the toothed belt wheel 40 of the lower roller III by way of the toothed belt 47 . Attached to the slider 36 a, in addition to the smooth guide pulley wheel 46 , is a further smooth guide pulley wheel 51 . The endless toothed belt 47 loops around, in succession, the pulley wheels 44 , 46 , 40 , 51 and 43 . The toothed belt wheels 44 , 40 and 43 are in engagement with the teeth of the toothed belt 47 , whereas the smooth guide pulley wheels 46 and 51 are in engagement with the smooth reverse side of the toothed belt 47 . The sliders 35 a and 36 a are rigidly connected to one another, releasably, by means of the bridge 50 . When they are not connected by the bridge 50 , the sliders 35 a and 36 a are individually displaceable and when they are connected by the bridge 50 they are jointly displaceable.
In accordance with FIG. 10, the drive motor 19 for lower rollers II and III is in communication with the electronic control and regulation device 26 . Adjustment values for modification of the draft zones VV and HV (that is to say the extents of the drawing zones) either can be entered manually by way of the input device 29 or can be called up from a memory 31 for particular categories of fibre material.
Adjustment of the nip line spacing in the preliminary draft zone VV and/or the main draft zone HV can be carried out with the fibre slivers 5 inserted.
Displacement can be carried out with the upper rollers 11 to 14 in the loaded state. FIGS. 1 and 10 show inserted fibre slivers 5 and loaded upper rollers 11 to 14 . With the fibre slivers inserted and the upper rollers 11 to 14 loaded, the sliders 35 a, 36 a or mountings of at least one lower roller II, III are unlocked, the sliders or mountings are set to the desired nip line spacing a, a′; b, b′ by means of a displacement device, for example in accordance with FIGS. 3 a , 3 b ; 5 a, 5 b and then the sliders 35 a, 36 a or mountings are locked again (for example in accordance with FIG. 7 ).
Displacement can also be carried out with the upper rollers 11 to 14 lifted off. The upper rollers 11 to 14 may be lifted off completely from the lower rollers I to III in the manner shown in DE-OS 197 04 815, the upper roller 14 being swung out on a portal 58 about a pivot mounting 59 . However, it may also be sufficient for the upper rollers 11 to 14 to be unloaded and to be lifted off from the lower rollers I to III only to a slight degree such that the fibre slivers 5 are not caught by the pairs of rollers during displacement of the draft zones VV and HV but can slide through the roller nip without being advrsely affected.
The invention has been illustrated using the example of the adjustment of the nip line spacings of a drawing mechanism of a draw frame. It likewise encompasses the adjustment of drawing mechanisms of other machines, for example carding machines, combing machines, fly frames and ring spinning frames. | A drawing mechanism for the doubling and drafting of fiber slivers has a drawing mechanism frame for accommodating the drawing mechanism, which has at least two pairs of rollers each comprising an upper roller and a lower roller and has means for adjusting the spacing of at least one of the lower rollers in relation to another lower roller, in each case having a mounting device for accommodating the lower roller, lower rollers are arranged to be driven by a drive device comprising at least one drive element endlessly revolving around pulley wheels and each lower roller has a roller-driving pulley wheel.
In order, by simple means in terms of construction, to make possible a considerable reduction in the work and time required for adjustment of the mounting devices and, accordingly, of the extent(s) of the drawing zone(s) without re-tensioning of the drive belt after the adjustment, at least one guide pulley wheel is attached to each mounting device, and the roller-driving pulley wheel and guide pulley wheel act, in each case one after the other, on both sides of the tensioned drive element. | 3 |
BACKGROUND
[0001] The present exemplary embodiment relates generally to processing an electronic document file for printing on a select printer. It finds particular application when the electronic document file includes print parameter information associated with a former printer that are at least not fully compatible with a new printer. However, it is to be appreciated that the exemplary embodiments described herein are also amenable to printing any electronic document file that includes print parameter information associated with a different printer than the printer selected for printing.
[0002] Traditionally, vendors have a hard time entering into environments where competitors have an established presence. Customers tend to resist changing what already works for them for a variety of reasons. When a customer does change to a different vendor's devices, the new vendor works with the customer in order to provide a smooth transition.
[0003] One issue that arises during this transition period is that the customer may find that their documents, which used to print correctly on previous vendor's devices, do not print correctly on the new vendor's devices. The root causes tend to be differences in media sizes, media types, and input tray selection, or differences between vendor-specific features.
[0004] Device vendors tend to release printer drivers that allow consistency amongst their own devices and do little to no work to ensure any compatibility between devices from other vendors. In fact, it's often advantageous to promote maximum incompatibility between devices from other vendors in order to make customers reluctant to switch vendors.
[0005] The customers do not care what the root causes are, their only concern is that when they printed on the previous vendor's devices, what used to print correctly now does not, forcing them to re-print documents and waste valuable resources. One way to resolve this issue is to limit replacement of current vendor devices to devices from other vendors that are more compatible. With this approach, the customer has to trade off new functionality with compatibility. Another way to resolve the issue is to revise all the customer documents to be compatible with the new vendor's devices. The customer is likely to lose revenue after deciding to switch to another vendor's device even if some of the incompatibility issues are resolved because of the amount of work required in modifying documents. Under these circumstances, the customer may remain with the current vendor and the potential new vendor loses revenue from losing the potential new customer.
INCORPORATION BY REFERENCE
[0006] None.
BRIEF DESCRIPTION
[0007] In one aspect, a method for processing an electronic document file for printing in provided. In one embodiment, the method includes: a) receiving an electronic document file for printing on a select printer at a print driver for the select printer; b) determining the electronic document file includes at least some different print parameter information associated with a different printer based at least in part on configuration data, wherein the configuration data includes mapping information between different print parameter information associated with the different printer and select printer information associated with the select printer, wherein the different print parameter information and the at least some different print parameter information are at least not fully compatible with the select printer; c) identifying and transforming the at least some different print parameter information to corresponding select print parameter information based at least in part on the mapping information; d) processing document print parameter information associated with the electronic document file received in a), wherein at least a portion of the document print parameter information was transformed from the at least some different print parameter information identified in c); and e) sending a print stream from the print driver to the select printer for printing the electronic document file in a manner consistent with the at least some different print parameter information.
[0008] In another aspect, an apparatus for processing an electronic document file for printing is provided. In one embodiment, the apparatus includes: a storage device storing a print driver associated with a select printer and a configuration file accessible to the print driver, wherein the configuration data includes mapping information between different print parameter information associated with a different printer and select print parameter information associated with the select printer, wherein the different print parameter information is at least not fully compatible with the select printer; and a processor in operative communication with the storage device to selectively use the print driver in conjunction with printing an electronic document file on the select printer. In this embodiment, the print driver includes: an input module that receives the electronic document file for printing on the select printer; a filter module in operative communication with the input module and the storage device to access the configuration data, wherein the filter module uses the configuration data to determine the electronic document file includes at least some different print parameter information, wherein the at least some different print parameter information is at least not fully compatible with the select printer; a mapping module in operative communication with the filter module and the storage device to use the configuration data to identify and transform the at least some different print parameter information to corresponding select print parameter information based at least in part on the mapping information; a processing module in operative communication with the filter module and the mapping module to process document print parameter information associated with the electronic document file, wherein at least a portion of the document print parameter information was transformed from the at least some different print parameter information; and an output module that sends a print stream to the select printer for printing the electronic document file in a manner consistent with the at least some different print parameter information.
[0009] In yet another aspect, another method for processing an electronic document file for printing is provided. In one embodiment, the method includes: a) generating mapping information between different print parameter information associated with a different printer and select print parameter information associated with a select printer and storing the mapping information in configuration data, wherein the different print parameter information is at least not fully compatible with the select printer; b) receiving an electronic document file for printing on the select printer at a print driver for the select printer; c) determining the electronic document file includes at least some different print parameter information based at least in part on the configuration data, wherein the at least some different print parameter information is at least not fully compatible with the select printer; d) identifying and transforming the at least some different print parameter information to corresponding select print parameter information based at least in part on the mapping information; e) processing document print parameter information associated with the electronic document file received in b), wherein at least a portion of the document print parameter information was transformed from the at least some different print parameter information identified in d); and f) sending a print stream from the print driver to the select printer for printing the electronic document file in a manner consistent with the at least some different print parameter information.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a screen view of an exemplary dialog box associated with an exemplary embodiment of a mapping tool for mapping print parameter information between different printers;
[0011] FIG. 2 is a screen view of another exemplary dialog box associated with an exemplary embodiment of a mapping tool for mapping print parameter information between different printers;
[0012] FIG. 3 is a screen view of yet another exemplary dialog box associated with an exemplary embodiment of a mapping tool for mapping print parameter information between different printers;
[0013] FIG. 4 is a screen view of still another exemplary dialog box associated with an exemplary embodiment of a mapping tool for mapping print parameter information between different printers;
[0014] FIG. 5 is a screen view of still yet another exemplary dialog box associated with an exemplary embodiment of a mapping tool for mapping print parameter information between different printers;
[0015] FIG. 6 is a screen view of an exemplary dialog box associated with a software application program showing selection of a paper source in conjunction with an exemplary embodiment of a print driver supporting options provided by a select printer;
[0016] FIG. 7 is a screen view of an exemplary dialog box associated with a software application program showing selection of a paper source in conjunction with an exemplary embodiment of a print driver supporting options provided by both a select printer and a different printer;
[0017] FIG. 8 is a flowchart showing an exemplary embodiment of a process for processing an electronic document file for printing;
[0018] FIG. 9 is a block diagram of an exemplary embodiment of a system for processing an electronic document file for printing;
[0019] FIG. 10 is a block diagram of another exemplary embodiment of a system for processing an electronic document file for printing that includes an exemplary mapping tool for generating mapping information for use in conjunction with the printing; and
[0020] FIG. 11 is a flowchart showing another exemplary embodiment of a process for processing an electronic document file for printing.
DETAILED DESCRIPTION
[0021] This disclosure describes various embodiments of methods and systems in which a select print driver can be dynamically configured to allow customers to map information for media sizes, type, media input trays, or any variety of features not specifically supported by a corresponding select printer or family of select printers with which the select print driver is used. Print driver pre-configuration files may be generated before the select print driver is installed and loaded when the select print driver is installed or invoked. The select print driver may automatically make internal adjustments to utilize the information from different print drivers and present options supported by different printers with which the different print drivers are used as if such options were supported by the select printer.
[0022] A mapping tool associated with the select printer could be used to allow a user (e.g., Systems Administrator, customer, or sales representative) to examine a different print driver and collect different print parameter information to allow the select print driver to mimic features associated with the different printer. The different print parameter information may include, but not be limited to, display strings used by the different print driver and any required IDs used to correctly select the different specified attributes in the application. Features, such as media size, may also require media dimensions.
[0023] The mapping tool may also provide a user interface showing such things as input trays for the different printer and available input trays for the select. For example, the mapping tool may allow users to select a tray for the different printer and a corresponding tray for the select printer to be utilized when the tray for the different printer is selected. The screen shots in FIGS. 1-5 show exemplary dialog boxes associated with an exemplary embodiment of a mapping tool. Once the user is satisfied with the mapping of the different print driver features to the select print driver features, the mappings information may be saved to a configuration file or operating system specific features, such as a Registry, for use by the select print driver.
[0024] In order to fully utilize the select print driver, the mapping tool may be used in conjunction with an existing environment with the different printer that is being replaced by the select printer. Additionally, some mechanism may be used to provide the configuration data with the different printer-to-select printer mappings. This mechanism could be as simple as a Windows registry file that is added to a client PC being used for printing. A more complex mechanism could use a server in the “cloud” (e.g., communication network accessible to the client PC via any suitable network and/or gateway) that enables delivery of a preconfigured configuration file along with the select print driver without breaking digital signatures to push the mapping information to the client PC used for printing via an automated process.
[0025] Once the configuration data with appropriate mapping information has been made available to the select print driver, the select print driver may automatically configure itself each time it is loaded by the operating system to mimic the different print driver. No additional interaction by the user is required at print time except that which is normally required to print documents.
[0026] From a customer's perspective, they can get the improved performance expected from the select print driver without having to determine if any changes to existing documents are required in order for them to be compatible with the select printer. Even though the select printer may provide only select printer options, the UI for the select print driver may present options for both the select printer and the different printer. If possible, the select printer options may be presented first. Some software program applications sort the string for certain print parameter information presented in the print driver UI alphabetically. For these applications, the options for the select printer and the different printer may be intermixed in the display order. The information may be displayed in any suitable manner.
[0027] FIG. 6 shows a screen view of an exemplary dialog box associated with Microsoft Word for selection of a paper source in conjunction with an exemplary embodiment of a select print driver supporting options provided only by a select printer. Alternatively, FIG. 7 shows a screen view of an exemplary dialog box associated with Microsoft Word for selection of a paper source in conjunction with an exemplary embodiment of a select print driver supporting options provided by both a select printer and a different printer.
[0028] Internally, within the select print driver, constraints and restrictions imposed on the various printing features still apply. As far as the select print driver is concerned, the user is simply utilizing select printer—regardless of whether the user is using the select print driver in conjunction with a software application program to select a feature support by the different printer to print on the select printer. In other words, no special actions are required by the user and printing is accomplished in the same manner with which they were accustomed when using the different printer.
[0029] Gradually, customers are expected to migrate to the capabilities of the select printer as they create and/or modify their documents. For example, if possible, each time a document is saved it may be automatically updated to utilize features of the select printer. However, if the customer does not modify a particular document, no further action will be required because the document will continue to print in the same manner as it did before a transition from the different printer to the select printer.
[0030] This ability to “mimic” a different print driver may give the vendor for the select printer a distinct advantage over its competitors. For example, this may allow the vendor for the select printer to move into customer sites that have previously been resistant to switch to a new printer. Additionally, the select print driver can be extended to include a variety of other features supported by many different printers. Support costs may go down for the customer because they will not have to be assisted in learning how to map existing document features to features of the select printer. The select print driver could also be used to transition from older versions of printers to an updated version of the printer from the same vendor.
[0031] Additionally, customers that decide to switch from the select printer to an environment with a new printer from a previous vendor or yet another vendor may be faced with exactly the same issue and may again use an embodiment of the process described herein to transition again without having to change existing documents that had been setup to print on any previous printers.
[0032] In summary, an electronic document file created by a software application (e.g., Microsoft Word) can have printer-specific information for a former printer or family of printers embedded within it. The printer-specific information may include paper sizes, paper trays, and paper types that the former printer or family of printers support. However, the printer-specific information embedded in the electronic document file may not be supported by other printers or families of printers. The various embodiments of methods and apparatus disclosed herein enable a new print driver for a new printer or family of printers can be configured such that the new printer or family of printers can cleanly print an electronic document file with embedded printer-specific information that is compatible with a former printer or family of printers and at least not fully compatible with the new printer or family of printers. In short, this makes the new print driver compatible with the former print driver so that electronic document files created with embedded printer-specific information for the former printer or family of printers can be printed on the new printer or family of printers without having to edit or alter the embedded printer-specific information. This enables printing of documents on the new printer or family of printers that were previously intended to be printed on the former printer or family of printers.
[0033] In one embodiment, a user would use a printer information mapping tool to specify how embedded printer-specific information (e.g., paper sizes, paper trays, paper types, etc.) for the former printer or family of printer maps to corresponding printer information for the new printer or family of printers. When the mappings are completed, the mapping tool produces configuration data containing the mappings. The new print driver imports the mapping information associated with the configuration data. The new print driver uses this mapping information to present a combined list that includes printer information for both the new printer and the former printer. When printing a document containing printer information associated with the former printer, the new print driver uses the mapping information to transform the printer information associated with the former printer into corresponding printer information associated with the new printer so that when the electronic document file prints on the new printer the document produced is consistent with documents that would be produced by the former printer.
[0034] For example, this facilitates transition of a user's printer or family of printers to another printer or family of printers by providing a means for existing electronic document files to satisfactorily print on the new printer or family of printers. This is especially useful for streamlining installation of a new printer or family of printers with minimal disruption to users.
[0035] With reference to FIG. 8 , an exemplary embodiment of a process 800 for processing an electronic document file for printing begins at 802 where an electronic document file may be received for printing on a select printer at a print driver for the select printer. Next, the process may determine the electronic document file includes at least some different print parameter information associated with a different printer based at least in part on configuration data ( 804 ). The configuration data may include mapping information between different print parameter information associated with the different printer and select printer information associated with the select printer. The different print parameter information and the at least some different print parameter information may be at least not fully compatible with the select printer.
[0036] At 806 , the at least some different print parameter information may be identified and transformed to corresponding select print parameter information based at least in part on the mapping information. Next, document print parameter information associated with the electronic document file received in 802 may be processed ( 808 ). At least a portion of the document print parameter information may have been transformed from the at least some different print parameter information identified in 806 . At 810 , a print stream may be sent from the print driver to the select printer for printing the electronic document file in a manner consistent with the at least some different print parameter information.
[0037] In another embodiment, the process 800 may also include generating the mapping information used in 804 and 806 using a mapping tool. The mapping information may be based at least in part on comparing the different print parameter information to the select print parameter information. In a further embodiment, the comparing and generating may be performed automatically in response to the mapping tool being initiated by a user. Alternatively, in another further embodiment, the comparing and mapping may be performed interactively via a user interface in response to the mapping tool being initiated by a user and the generating of the mapping information may be performed automatically in response to a user activation via the user interface indicating the comparing and mapping is complete. In yet another further embodiment, the comparing and generating may be performed automatically in conjunction with installation of the print driver.
[0038] In yet another embodiment of the process 800 , the select printer and the print driver are co-located in a computer system. In a further embodiment, the computer system is a server system. Alternatively, in another further embodiment, the computer system is a stand-alone computer workstation. In still another embodiment of the process 800 , the select printer is a network device associated with a computer network and the print driver is located within a networked computer workstation in operative communication with the select printer via the computer network.
[0039] With reference to FIG. 9 , an exemplary embodiment of a system 900 for processing an electronic document file 902 to form a print stream 904 for printing on a select printer 906 may include a storage device 908 and a processor 910 . The storage device 908 may store a print driver 912 associated with the select printer 906 and configuration data 914 accessible to the print driver 912 . The configuration data 914 will include mapping information 916 between different print parameter information associated with a different printer and select print parameter information associated with the select printer 906 . The different print parameter information may be at least not fully compatible with the select printer 906 . The processor 910 may be in operative communication with the storage device 908 to selectively use the print driver 912 in conjunction with printing the electronic document file 902 on the select printer 906 .
[0040] In this embodiment, the print driver 912 may include an input module 918 , a filter module 920 , a mapping module 922 , a processing module 924 , and an output module 926 . The input module 918 may receive the electronic document file 902 for printing on the select printer 906 . The filter module 920 may be in operative communication with the input module 918 and the storage device 908 to access the configuration data 914 . The filter module 920 may use the configuration data 914 to determine the electronic document file 902 includes at least some different print parameter information. The at least some different print parameter information may be at least not fully compatible with the select printer 906 . The mapping module 922 may be operative communication with the filter module 920 and the storage device 908 to use the configuration data 914 to identify and transform the at least some different print parameter information to corresponding select print parameter information based at least in part on the mapping information 916 . The processing module 924 may be operative communication with the filter module 920 and the mapping module 922 to process document print parameter information associated with the electronic document file 902 . At least a portion of the document print parameter information may be transformed from the at least some different print parameter information. The output module 926 may send the print stream 904 to the select printer 906 for printing the electronic document file 902 in a manner consistent with the at least some different print parameter information.
[0041] With reference to FIG. 10 , another exemplary embodiment of a system 1000 for processing an electronic document file may include a mapping tool 1028 in operative communication with the storage device 1008 to generate mapping information 1016 based at least in part on comparing different print parameter information 1030 to select print parameter information 1032 . The mapping information 1016 may be stored on the storage device 1008 in the configuration data 1016 . In a further embodiment, the mapping tool 1028 may automatically compare the different print parameter information 1030 to the select print parameter information 1032 to generate the mapping information 1016 in response to being initiated by a user. Alternatively, in another further embodiment, the mapping tool 1028 may include a user interface module 1034 to enable the user to interactively compare and map the different print parameter information 1030 to the select print parameter information 1032 . In this embodiment, the mapping tool 1028 may generate the mapping information 1016 in response to a user activation via the user interface 1034 indicating the comparing and mapping is complete. In still another further embodiment, the print driver 1012 may include the mapping tool 1028 . In this embodiment, the mapping tool 1028 may be initiated automatically to compare the different print parameter information 1030 to the select print parameter information 1032 to generate the mapping information 1016 in conjunction with installation of the print driver 1012 on the storage device 1008 .
[0042] With reference again to FIG. 9 , in another embodiment of the system 900 , the storage device 908 and processor 910 may be co-located in a computer system. In a further embodiment, the computer system may be a server system. Alternatively, in another further embodiment, the computer system may be a networked computer workstation. In still another further alternate embodiment, the computer system may be a stand-alone computer workstation.
[0043] With reference to FIG. 11 , an exemplary embodiment of a process 1100 for processing an electronic document file for printing begins at 1102 where mapping information between different print parameter information associated with a different printer and select print parameter information associated with a select printer may be generated and stored in a configuration file or operating system specific feature, such as a Registry. The different print parameter information may be at least not fully compatible with the select printer. Next, an electronic document file may be received for printing on the select printer at a print driver for the select printer ( 1104 ). At 1106 , the process may determine the electronic document file includes at least some different print parameter information based at least in part on the configuration data. The at least some different print parameter information may be at least not fully compatible with the select printer. Next, the at least some different print parameter information may be identified and transformed to corresponding select print parameter information based at least in part on the mapping information ( 1108 ). At 1110 , document print parameter information associated with the electronic document file received in 1104 may be processed. At least a portion of the document print parameter information may be transformed from the at least some different print parameter information identified in 1108 . Next, a print stream may be sent from the print driver to the select printer for printing the electronic document file in a manner consistent with the at least some different print parameter information ( 1112 )
[0044] It will be appreciated that several of the above-disclosed and other features and functions, or alternatives thereof, may be desirably combined into many other different systems or applications. Also that various presently unforeseen or unanticipated alternatives, modifications, variations or improvements therein may be subsequently made by those skilled in the art which are also intended to be encompassed by the following claims. | A method for processing an electronic document file for printing may include receiving an electronic document file at a print driver for a select printer; determining the electronic document file includes different print parameter information for a different printer based on configuration data; identifying and transforming the different print parameter information to select print parameter information based on mapping information; processing document print parameter information associated with the electronic document file, where a portion of the document print parameter information was transformed from the different print parameter information; and sending a print stream to the select printer for printing the electronic document file consistent with the different print parameter information. A related system may include a storage device and a processor. The storage device may include the print driver and configuration data with the mapping information. The print driver may include input; filter; mapping; processing; and output modules. | 6 |
This is a continuation of application Ser. No. 08/057,853 filed May 7, 1993, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a process for the (co)polymerisation of olefins, in particular of ethylene, using a number of reactors arranged in series. It also relates to olefinic block (co)polymers having a polymodal molecular weight distribution and in particular to such block (co)polymers comprising ethylene, typically polyethylene.
DESCRIPTION OF THE RELATED ART
U.S. Pat. No. 3,392,213 (Shell Oil Company) describes a process for the polymerisation of olefins, according to which a number of polymerisation reactors connected in series are used, the olefin is polymerised in the presence of the catalyst in the first reactor of the series, a polymer and the catalyst are drawn off from this first reactor, they are introduced into the following reactor which is additionally supplied with the olefin, the polymerisation is continued in this reactor and in the following reactors, each supplied with olefin and with the product arising from the preceding reactor, hydrogen is introduced into one at least of the reactors and, from the last reactor, a polyolefin is recovered which has a broad molecular weight distribution. In this known process, the catalyst used is of Ziegler type and comprises a transition metal compound and an organometallic compound.
This known process requires the use of a cocatalyst (organometallic compound). The presence of a cocatalyst during the polymerisation has the consequence that the polyolefins obtained generally have a high oligomer content. Now oligomers harm the mechanical and rheological properties of polyolefins, restricting their applications due to their considerable solubility at room temperature and cause fumes when the polyolefins are used at high temperature. Moreover, with this known process, adjustment of the molecular weight distribution is not generally very precise, which does not make it possible to produce polyolefins having predetermined properties.
SUMMARY OF THE INVENTION
The invention overcomes the disadvantages of the known process described above by providing a new process which makes it possible to produce block (co)polymers having a low oligomer content and which additionally results in better precision in adjusting the melt index of the polyolefins produced. The process according to the invention consequently makes it possible to produce block (co)polymers having improved mechanical and rheological properties.
Consequently, the invention relates to a process for the (co)polymerisation of at least one olefin according to which at least two polymerisation reactors are used, a portion of the olefin is polymerised in one of the reactors in the presence of a catalyst, a composition comprising a polymer and the catalyst is drawn off from this reactor and the composition and another portion of the olefin are introduced into the other reactor, hydrogen being introduced into one at least of the reactors; according to the invention, optionally substituted bis(cyclopentadienyl)chromium, on an inorganic oxide support, is used as catalyst.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the process according to the invention, the olefin is not critical and may, for example, contain up to 20 carbon atoms per molecule. It advantageously contains from 2 to 8 carbon atoms per molecule and comprises, for example, ethylene, propylene, 1-butene, 1-pentene, 3-methyl -1-butene, 1-hexene, 3- and 4-methyl1-pentenes, 1-octene, 3-ethyl-1-butene, 1-heptene, 1-decene, 4,4-dimethyl -1-pentene, 4,4-diethylhexene, 3,4-dimethyl-1-hexene, 4-butyl-1-octene, 5-ethyl-1-decene and 3,3-dimethyl-1-butene.
In the process according to the invention, the polymer which is drawn off from the first reactor is obtained in this reactor by polymerisation of a portion of the olefin in the presence of a catalyst.
According to the invention, the catalyst is bis(cyclopentadienyl)chromium represented by the formula (C 5 H 5 )-Cr-(C 5 H 5 ), or a substituted bis(cyclopentadienyl)chromium compound, represented by the formula (C 5 RABCD)-Cr-(C 5 A'B'C'D'E'), where R denotes a hydrocarbon radical having up to 20 carbon atoms, and A, B, C, D, A', B', C', D' and E' each denote a hydrogen atom or a hydrocarbon radical having up to 20 carbon atoms. The hydrocarbon radicals may be saturated or unsaturated and they may comprise, for example, aliphatic radicals such as a methyl, propyl, butyl or allyl radical, alicyclic radicals such as a cyclopentyl, cyclohexyl or cycloheptyl radical, and aromatic radicals such as a phenyl or naphthyl radical. Unsubstituted bis(cyclopentadienyl)chromium is preferably used.
Bis(cyclopentadienyl)chromium and its substituted compounds described above may be obtained by the preparation processes disclosed in the Patents U.S. Pat. No. 4,077,904 (Union Carbide Corporation) and U.S. Pat. No. 3,709,853 (Union Carbide Corporation), where it is used as a catalyst for producing polyethylene having a narrow molecular weight distribution.
In the process according to the invention, optionally substituted bis(cyclopentadienyl)chromium is deposited on a support. To this end, there may be used, for example, an inorganic oxide chosen from the oxides of silicon, aluminium, titanium, zirconium or thorium and their mixtures such as aluminium silicate, the inorganic oxides activated by fluorination and aluminium phosphate. Silica and aluminium phosphate are well suited, in particular silica. The support and the catalyst may be obtained as described in the U.S. Pat. No. 3,709,853 (Union Carbide Corporation) and U.S. Pat. No. 4,077,904 (Union Carbide Corporation).
In the process according to the invention, a plant is used comprising at least two polymerisation reactors arranged in series and connected to each other. Each reactor is supplied with olefin. The catalyst is introduced solely into the first reactor, in which the olefin is polymerised until a polymer is obtained which has the characteristics appropriate for the polymerisation conditions of this reactor. The composition arising from the first reactor and comprising the polymer obtained and the catalyst is transferred into the following reactor, preferably continuously. In this second reactor, the olefin which is introduced therein is polymerised using the catalyst arising from the preceding reactor. Hydrogen, as transfer agent adjusting the molecular weight of the polymer obtained, is introduced continuously or non-continuously into at least one of the reactors. Preferably, both the polymerisation reactors are supplied with hydrogen so that the concentration of hydrogen in the first reactor is different from the concentration of hydrogen in the second reactor. By thus using in the second reactor polymerisation conditions which are different from those used in the first reactor, the polymer produced in the second reactor has a molecular weight different from that produced in the first, and the overall polymerised product obtained combines the characteristics appropriate for the operating conditions of the first and of the second reactor. The plant may obviously comprise more than two reactors connected in series which are supplied separately with olefin and with the composition arising from the preceding reactor of the series. Preferably, two reactors arranged in series are used.
In the process according to the invention, the polymerisation process in the first reactor is selected from the solution, suspension or gas-phase processes, regardless of the choice of process used in the other reactor. It is possible, for example, to carry out the polymerisation in both reactors in the gas phase, or in the first reactor in suspension and in the second in the gas phase.
In the case of a suspension polymerisation, the latter is carried out in a hydrocarbon diluent which is inert with respect to the catalyst and to the polyolefin produced, such as liquid aliphatic, cycloaliphatic and aromatic hydrocarbons, at a temperature such that at least 50% (preferably at least 70%) of the polymer formed is insoluble therein. The preferred diluents are linear alkanes such as n-butane, n-hexane and n-heptane, or branched alkanes such as isobutane, isopentane, isooctane and 2,2-dimethylpropane, or cycloalkanes such as cyclopentane and cyclohexane, or their mixtures. The polymerisation temperature is generally chosen from 20° to 200° C., preferably from 50° to 100° C. The olefin partial pressure is most often chosen from atmospheric pressure to 5 MPa, preferably from 0.4 to 2 MPa, and more particularly from 0.6 to 1.5 MPa.
In the case of a solution polymerisation, the latter may be carried out in an inert organic diluent such as described above. The operating temperature depends on the organic diluent used and must be greater than the dissolution temperature of the polyolefin in this organic diluent, so that at least 50% (preferably at least 70%) of the polyolefin is dissolved therein. Moreover, the temperature must be sufficiently low to prevent thermal degradation of the polyolefin and/or of the catalyst. Generally, the optimum temperature is from 100° to 200° C. The olefin partial pressure is most often chosen from atmospheric pressure to 5 MPa, preferably from 0.4 to 2 MPa and more particularly from 0.6 to 1.5 MPa. It is also possible to carry out the solution polymerisation without adding diluent, the olefin itself constituting the reaction medium. In this embodiment, it is possible to use a liquid olefin under normal pressure and temperature conditions or to carry out the reaction under a pressure which is sufficient for a normally gaseous olefin to be liquefied.
In the case where the polymerisation is carried out in the gas phase, a gas stream comprising the olefin is brought into contact with the catalyst in a fluidised bed. The flow rate of the gas stream must consequently be sufficient to maintain the polyolefin in fluidisation and depends on the rate of formation of the latter and on the rate at which the catalyst is consumed. The olefin partial pressure may be lower than or greater than atmospheric pressure, the preferred partial pressure being from atmospheric pressure to approximately 7 MPa. A pressure from 0.2 to 5 MPa is generally well suited. The choice of temperature is not critical and the latter is generally from 30° to 200° C. It is optionally possible to use a dilution gas, which must be inert with respect to the olefin.
In the process according to the invention, each reactor is supplied with olefin and at least one of the reactors is supplied with hydrogen. The hydrogen partial pressure in the reactor is advantageously from 0.01 to 0.50 MPa, more particularly from 0.015 to 0.40 MPa and preferably from 0.018 to 0.35 MPa, the ratio of the hydrogen to olefin partial pressures not exceeding 3, generally not exceeding 1/3 and being, for example, from 0.01 to 0.30.
In the process according to the invention, it is optionally possible to use a cocatalyst in addition to the bis(cyclopentadienyl)chromium.
However, it is preferred, according to an advantageous embodiment of the process according to the invention, that the catalyst consists of bis(cyclopentadienyl)chromium without cocatalyst. This embodiment has the advantage of reducing the formation of oligomers during the polymerisation.
In another embodiment of the process according to the invention, hydrogen is introduced continuously into at least one of the reactors, the ratio of the hydrogen partial pressure to that of the olefin in the reactor being constant during the time required for the production of a defined amount of polymer, and not exceeding 3, generally not exceeding 1/3. In this embodiment, the hydrogen partial pressure in the reactor is advantageously from 0.01 to 0.50 MPa, more particularly from 0.015 to 0.40 MPa and preferably from 0.018 to 0.35 MPa, and the ratio of hydrogen to olefin partial pressures is from 0.01 to 0.30.
In a preferred embodiment of the process according to the invention, both reactors may be supplied with hydrogen, the ratio of olefin to hydrogen partial pressures in the first reactor being different from that used in the second reactor. In this embodiment, it is important to maintain these ratios constant in each reactor for the duration of the polymerisation. The quotient of these two ratios is advantageously greater than 5, preferably than 10; it is desirable that it does not exceed 100, for example 80. In the case of polyethylene, a quotient from 10 to 50 may, for example, be selected.
The process according to the invention applies in particular to the polymerisation of olefin, preferably ethylene, homopolymers. The process according to the invention is also well suited to the copolymerisation of olefins, preferably of ethylene, with olefinically unsaturated comonomers comprising up to 8 carbon atoms. Diolefins comprising from 4 to 18 carbon atoms may also be copolymerised with ethylene. Preferably, the diolefins are nonconjugated aliphatic diolefins such as 4'-vinylcyclohexene and 1,5-hexadiene, or alicyclic diolefins having an endocyclic bridge such as dicyclopentadiene or methylene- and ethylidenenorbornene, and conjugated aliphatic diolefins such as 1,3-butadiene, isoprene and 1,3-pentadiene.
The process according to the invention is particularly well suited to the manufacture of ethylene homopolymers and of copolymers containing at least 90%, preferably at least 95%, by weight of ethylene. The preferred comonomers are chosen from propylene, 1-butene, 1-hexene and 1-octene.
The process according to the invention has the advantageous characteristic that it does not require the use of a cocatalyst, generally a pyrophoric product; this results in easier control of the operating parameters of the polymerisation.
The process according to the invention makes it possible to produce homopolymers and copolymers having a polymodal molecular weight distribution. These polymers comprise a number of polymer blocks each having a narrow molecular weight distribution, the mean molecular weights of the blocks being different. The process according to the invention especially makes it possible to manufacture homo- or copolymers characterised by an M w /M n ratio from 10 to 60, where M w and M n respectively denote the weight-average molecular weight and the number-average molecular weight of the polyolefin produced.
The process according to the invention moreover makes it possible to produce polyolefins comprising at least two polymer blocks, of different melt indices, generally from 0.1 to 1,000 g/10 min. The ratio of these melt indices in the two blocks can thus reach a maximum value of 10,000. Moreover, the process according to the invention also makes it possible to produce block (co)polymers having a low oligomer content not exceeding 15% of the polyolefin weight and generally less than 7% of the polyolefin weight. It especially makes it possible to produce block (co)polymers whose oligomer content does not exceed 5% by weight and may fall to 0.5% by weight.
The invention consequently also relates to block (co)polymers, preferably comprising polyethylene, having a maximum oligomer content equal to 15% (generally from 0.5 to 5%) of its weight and a M w /M n ratio from 10 to 60, the blocks having different melt indices from 0.1 to 1,000 g/10 min. The invention in particular relates to the (co)polymers obtained using the process according to the invention and having the characteristics stated above. Oligomers are understood to denote polymers comprising a maximum of 10 monomer units. Melt index is understood to denote that measured at 190° C. under a loading of 21.6 kg.
The (co)polymers according to the invention find a particularly advantageous use in a wide range of industrial applications as a result of combining good use properties and good mechanical properties such as impact strength and stress cracking resistance.
Examples which are described below are used to illustrate the invention. In these examples, catalysts were prepared which were then used to polymerise ethylene in suspension.
The meaning of the symbols used in these examples, the units expressing the quantities mentioned and the methods of measuring these quantities are explained below.
HLMI=melt index expressed while molten, measured under a loading of 21.6 kg at 190° C. and expressed in g/10 min according to the ASTM standard D 1238.
M w /M n =ratio of the weight-average molecular weight to the number-average molecular weight measured by steric exclusion chromatography carried out in 1,2,4-trichlorobenzene at 135° C. on a Waters type 150 C chromatograph.
η 0 =dynamic viscosity expressed in Pa.s and measured at a velocity gradient of 1 s -1 and at 190° C.
η 2 =dynamic viscosity expressed in Pa.s and measured at a velocity gradient of 100 s -1 and at 190° C.
01=oligomer content expressed in grams of oligomer per kilo of polyolefin and measured by extraction with hexane at its boiling temperature.
ESCR=stress cracking resistance expressed in hours and measured by the Bell method (ASTM standard D 1693).
Example 1 (in accordance with the invention)
A. Preparation of the catalyst
A solution of bis(cyclopentadienyl)chromium in toluene was prepared, which solution was then added to a predetermined amount of silica (Grace.sup.• 532 product), dehydrated under an inert atmosphere at a temperature of 815° C. for 16 h, so that the final chromium content is 1% by weight. The toluene was then removed under reduced pressure. The bis(cyclopentadienyl)chromium was then sublimed under reduced pressure onto the silica support for 5 hours. Return to atmospheric pressure was carried out under dry nitrogen and the catalyst obtained was stored with oxygen and water excluded.
B. Polymerisation of ethylene
The polymerisation process in two successive reactors was simulated in a single reactor in two stages separated by an intermediate pressure release and resetting of the operating parameters.
First stage:
90 mg of catalyst obtained in A and 1 liter of isobutane were introduced into a 3-liter autoclave, which was dried beforehand and equipped with a stirrer. The temperature was then raised to 70° C. and a single charge of hydrogen at a pressure of 0.22 MPa and ethylene were then introduced therein. The ethylene partial pressure was maintained constant at a value of 0.61 MPa during the time for the production of 140 g of polyethylene.
The autoclave was then cooled and degassed to a relative pressure of 0.05 MPa.
Second stage:
1 liter of isobutane was introduced into the autoclave. The temperature was brought to 70° C. A charge of hydrogen at a pressure of 0.01 MPa and ethylene were then introduced. The ethylene partial pressure was maintained constant at a value of 1.02 MPa until an additional amount of 140 g of polyethylene was obtained. After degassing, 280 g of polyethylene were collected from the autoclave in the form of grains. The following results were obtained:
HLMI=3.6
M w /M n =57.56
η 0 /η 2 =19.4
01=5.4.
Example 2 (in accordance with the invention)
A. Preparation of the catalyst
The catalyst was prepared by the method described in Example 1 (A).
B. Polymerisation of ethylene
The operations of Example 1 (B) were repeated under the following operating conditions:
First stage:
initial hydrogen partial pressure: 0.22 MPa
ethylene partial pressure: 0.61 MPa
amount of polyethylene produced: 425 g
Second stage:
initial hydrogen partial pressure: 0.01 MPa
ethylene partial pressure: 1.02 MPa
amount of polyethylene produced in the second stage: 425 g
total amount of polyethylene produced: 850 g
The following results were obtained:
HLMI=7.3
η o /η 2 =15.8
O1=8.9
ESCR=68.
Example 3 (for reference)
In this example, the polymerisation of ethylene was carried out using a Ziegler-type catalyst described in the U.S. Pat. No. 4,617,360 in the name of the Applicant, the operations of Example 1 (B) being repeated under the following operating conditions:
First stage:
initial hydrogen partial pressure: 0.9 MPa
ethylene partial pressure: 0.6 MPa
amount of polyethylene produced: 160 g
Second stage:
initial hydrogen partial pressure: 0.02 MPa
ethylene partial pressure: 0.4 MPa
amount of polyethylene produced in the second stage: 221 g.
total amount of polyethylene produced: 381 g
The following results were obtained:
HLMI=3.9
η 0 /η 2 =13.1
01=13.1. | A process for the polymerization of at least one olefin is a suspension process employing a hydrocarbon diluent such that at least 70% of the polymer formed is insoluble therein, and employs at least two polymerization reactors. The process includes introducing a first portion of the at least one olefin and a catalyst into a first reactor. The catalyst is composed of bis(cyclopentadienyl)chromium, which may be substituted, supported on an inorganic oxide support and is supplied solely into the first reactor. The at least one olefin is polymerized in the first reactor to provide a first composition composed of a polymer and the catalyst. The first composition is then drawn off from the first reactor and the first composition and another portion of the at least one olefin are introduced into a second reactor and the another portion of the at least one olefin is polymerized in the second reactor in the presence of the first composition. Further, hydrogen is introduced into at least one of the reactors at a partial pressure ranging from 0.01 to 0.50 MPa, the ratio of the hydrogen to olefin partial pressure in this reactor ranging from 0.01 to 3. Additionally, the olefin partial pressure in the at least two reactors ranges from atmospheric pressure to 5 MPa, and the polymerization in the at least two reactors is carried out at a temperature ranging from 50° to 100° C. | 2 |
CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation of U.S. application Ser. No. 08/228,147, filed Apr. 15, 1994, which issues as U.S. Pat. No. 5,423,996, on Jun. 13, 1995.
BACKGROUND OF THE INVENTION
The present invention relates to compositions for thermal energy storage or thermal energy generation, and more particularly, to a composition comprising a silica based gel or dry powder containing a water/urea phase change material for thermal energy storage or an endothermic or exothermic compound for thermal energy generation.
Phase change materials may be repeatedly converted between solid and liquid phases and utilize their latent heat of fusion to absorb, store and release heat or cool during such phase conversions.
These latent heats of fusion are greater than the sensible heat capacities of the materials. For example, in phase change materials, the amount of energy absorbed upon melting or released upon freezing is much greater than the amount of energy absorbed or released upon increasing or decreasing the temperature of the material over an increment of 10° C.
Upon melting and freezing, per unit weight, a phase change material absorbs and releases substantially more energy than a sensible heat storage material that is heated or cooled over the same temperature range. In contrast to a sensible heat storage material that absorbs and releases energy essentially uniformly over a broad temperature range, a phase change material absorbs and releases a large quantity of energy in the vicinity of its melting/freezing point.
Ice/water phase change materials are low-cost, widely-used phase change materials for temperature regulation at 0° C. Such phase change materials have found use in applications such as refrigeration, chilling of beverages, medical therapy, and frozen confections. The many applications for ice/water phase change material could be significantly increased if a means could be found to decrease the freezing temperature without a prohibitive concurrent decrease in thermal energy storage. Soluble additives such as salt, alcohol, glycol, glycerine, or sugar, all function to depress the freezing point of water to temperatures well below 0° C. but these additives also decrease the heat of fusion to 50% or less that of pure water. Further, such additives, when mixed with ice/water, are messy and inconvenient to use.
If, for example, ice/water could be made to freeze and melt congruently at a temperature in the range of -11° to -15° C., without a substantial decrease in the heat of fusion and crystallization, many new applications would become possible and current applications improved. The new modified ice/water could be used to freeze pure water, make ice cream, keep cold drinks colder, store cool for off-peak electrical air conditioning, and thermal energy storage of "cool" for diurnal and seasonal cooling. Thus it could be used in a device for making frozen confections such as that disclosed in Uesaka, U.S. Pat. No. 4,488,817. Uesaka discloses using a cold-keeping agent which comprises water or carbonated water with organic or inorganic salts added thereto in a double-walled vessel for that purpose.
Further, if there were a means for containing the new modified ice/water so as to encapsulate it or to render it a dry powder, then, its use could be greatly expanded beyond that discussed above. In my U.S. Pat. Nos. 5,106,520 and 5,282,994 there is disclosed a free flowing, conformable powder-like mix of silica particles and a phase change material which may include water. Still there is no disclosure of the use of a water/urea clathrate or inclusion compound as the phase change material.
Thus, while phase change materials for thermal energy storage are known, improved thermal energy storage materials would be desirable. Likewise, improved endothermic and exothermic compounds for thermal energy generation are also in demand.
Instant cold and instant hot products for medical therapy and other uses are known. There are a number of instant cold packs on the market based on ammonium nitrate/water. These products usually contain a freezing point depressant (to prevent freezing to a hard ice in reuse); and, in some cases, a gelling agent as well to produce a somewhat reusable gel. One of the instant hot products commercially available is based on supercooling of a salt hydrate, sodium acetate trihydrate, that is initiated by mechanical attrition to start crystallization and supply hot at about 50° C. The product can be reactivated by remelting in boiling water to provide limited reuse capability as a gel. With both the instant cold and instant hot products, the reusable gel has only a limited effectiveness and a limited useful life. Accordingly, a gel with a superior reuse capability would be advantageous. Perhaps even more advantageous would be a dry powder containing an endothermic or exothermic compound because of its soft conformability. As discussed above, dry powders containing phase change materials are disclosed in my U.S. Pat. Nos. 5,106,520 and 5,282,994, but there is no disclosure of using endothermic or exothermic compounds in that regard.
Accordingly, there is still a need in the art for improved compositions useful in thermal energy storage or thermal energy generation which are inexpensive and easy to use.
SUMMARY OF THE INVENTION
The present invention meets that need by providing a silica based gel or dry powder in the form of silica particles containing a water/urea phase change material for thermal energy storage or an endothermic or exothermic compound for thermal energy generation. In one embodiment, there is provided a water/urea phase change material contained in a particulate silica matrix. Preferably, the silica particles are hydrophobic silica particles surface treated with 0.5-5 parts per hundred by weight of a silane coupling agent or silicone resin. The mixture of silica and phase change material (PCM) is preferably in the form of a free-flowing, conformable powder-like mix, i.e. PCM/silica dry powder, which may be prepared in accordance with U.S. Pat. Nos. 5,106,520 or 5,282,994, which are incorporated herein by reference. The water/urea PCM/silica dry powder preferably has a thermal energy storage of greater than 30 cal/gm.
In this embodiment, the silica is preferably present in an amount of from 30 to 40% by weight and the water/urea phase change material is present in an amount of from 70 to 60% by weight. This type of structure is especially desirable for medical wrap applications, but is of interest in other applications such as for tableware. Thus, the PCM/silica dry powder may be disposed in a liquid impervious polymer film or a metal foil enclosure to form a medical wrap. The PCM/silica dry powder may also be disposed in the plastic housing of containers such as tableware items or ice cream freezers.
Likewise, the water/urea phase change material/silica dry powder composition may be disposed in the inner chamber of a housing where the housing includes an inner cavity for containing a heat sensitive item such as a flight recorder. Such a device is disclosed in copending application Serial No. 08/044,819, incorporated herein by reference.
The water/urea phase change material is a water/urea clathrate or inclusion compound which melts and freezes congruently in the range of about -11° C. to -15° C., and stores and releases over at least 50 cal/gram, preferably over 60 cal/gram, and up to 72 cal/gram of thermal energy in melting and freezing. The water/urea phase change material preferably is less than about 80% by weight water, preferably within the range of about 82-54.5%, and more preferably within the range 78-70% and at least about 20% by weight urea, preferably within the range 18-44.5% and more preferably within the range 22-30%. In the most preferred embodiment, the water/urea phase change material is about 75% by weight water and about 25% by weight urea.
The thermal energy storage composition of the present invention is useful in a variety of applications. For example, the composition may be used in medical wraps, food servingware, and "blue ice" for cold packs or food storage.
The water/urea phase change material may also be used in neat form. For example, the water/urea phase change material by itself may be disposed in a bag or container made of a liquid impervious polymer for use as "blue ice" or it may be disposed in the plastic housing of containers such as tableware items or ice cream freezers.
In another embodiment, there is provided a silica based gel or dry powder composition capable of generating high endothermic cool or exothermic hot, when activated by a liquid activating solution, such as water. When water, or another phase change material is used as the liquid activating agent, the composition is thereafter capable of being reused as a thermal energy storage device. For a compound to supply high endothermic cooling or exothermic heating, the chemical must have a high negative or positive heat of solution in a liquid activating solution such as water, a relatively low molecular weight, combined with high solubility in a liquid activating solution such as water (at or near ambient temperature). Additionally, the chemical must be non-toxic, environmentally safe, and available at reasonable cost.
For instant cooling, ammonium nitrate, which has a high molal endothermic heat of solution, low molecular weight, and high solubility in water, is non-toxic and low-cost. Urea also has a relatively high endothermic heat of solution (second to ammonium nitrate), and is non-toxic and is environmentally acceptable.
Accordingly, in the preferred embodiment for instant cold applications ammonium nitrate, urea, and combinations of these two chemicals are used with hydrophilic fumed or precipitated silica particles, with and without a freezing point depressant, to produce a reusable gel at lower silica concentrations (i.e. 20 to 30% by weight of the total composition); and a soft, comformable dry powder at higher silica concentrations (i.e. 30 to 40% by weight of the total composition). In this system, salt can function as a freezing point depressant to provide reuse capability in the gels, but is not essential in the dry powder compositions that contain a high amount of silica. However, in the gels or dry powder the urea can supply significant added thermal energy storage if it is added in solid powder form and mixed with the ammonium nitrate prior to activating the system with water.
The gels will have reuse capability only as sensible heat materials, since a freezing point depressant is present to prevent freezing to a hard lump of "ice." The dry powder, on the other hand, can be reused as a phase change material if recharged by freezing, and without forming a hard lump of ice.
Most of the compositions having the highest exothermic heat of solution and highest solubility present obvious problems of toxicity, thermal instability, etc. The hydration of calcium oxide (lime) with water produces excessively high temperatures and forms a solid brick. Still, this vigorous exothermic reaction may be of interest as a high-temperature heat source for non-medical use. The preferred exothermic material for medical therapy applications is calcium chloride. Calcium chloride may, thus, be added to hydrophilic fumed or precipitated silica particles to form a gel at lower concentrations of silica (i.e. 15 to 25% by weight of the total composition) and dry powders at higher concentrations of silica (i.e. 25 to 40% by weight of the total composition). If desired, added temperature exotherm may be obtained by a combination of one highly exothermic compound such as calcium chloride and a second exothermic compound such as calcium oxide, potassium carbonate or others.
Suitable means for containing the separate dry and liquid activating solution ingredients must be provided for the instant cold and instant hot systems. Film containers in which the liquid activating solution such as water is contained in a "rupturable" bag inside a larger bag containing the dry ingredients is one system that is described in the U.S. Pat. 3,874,504, which is incorporated herein by reference, and which may be used. However, to avoid the possibility of accidental activation, the water may be contained in a separate small bag attached to the outside of the larger bag. To activate the system, the larger bag is opened and the water poured therein and rapidly mixed to produce an instant hot gel or dry powder.
The primary use of the instant cold and instant hot gels and dry powders is probably for medical therapy where they supply sensible energy on a time/temperature thermocline. In this use they may supplement the thermal energy storage material based on the water/urea phase change material of the first embodiment discussed above. The instant cold and instant hot gels and dry powders can be activated anytime and anyplace, and have reuse capability. Additional applications for which the instant cold and instant hot gels and dry powders may be used include clothing and wearing apparel, home ice cream freezing, outdoor cooking, and seasonal thermal storage.
Accordingly, it is an object of the present invention to provide a composition for thermal energy storage or thermal energy generation comprising a silica based gel or dry powder containing a water/urea phase change material for thermal energy storage or an endothermic or exothermic compound for thermal energy generation. These, and other objects and advantages of the present invention, will become apparent from the following detailed description and the accompanying claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic view of a medical wrap utilizing the compositions of the invention;
FIG. 2 is a sectional view taken along the lines and arrows 2--2 shown in FIG. 1 wherein a water/urea phase change material/silica dry powder composition of one embodiment of the present invention is contained;
FIG. 2A is a magnified cut-away view showing the uniform nature of the water/urea phase change material/silica dry powder;
FIGS. 3A-3D show an elevational view, broken away, of formation of a pack for-thermal energy generation utilizing the endothermic or exothermic compound/silica dry powder composition of another embodiment of the present invention;
FIG. 4 is a diagrammatic view of a tableware item, a dinner serving tray, utilizing the compositions of the present invention; and
FIG. 5 is a sectional view taken along arrows 5--5 in FIG. 4.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings, FIGS. 1, 2 and 2A show a medical wrap 2, specifically an elbow joint wrap, comprising an outer envelope 4, formed from a liquid impervious material which may be a polymeric material such as a butadiene-acrylonitrile copolymer, a polyester such as polyethylene terephthalate or vinyl polymer such as plasticized polyvinyl chloride, plasticized polyvinylidene chloride, low and high density polyethylene and ethylene-vinylacetate copolymers or a metal foil such as aluminum foil. Housed within the liquid impervious outer envelope is a powder-like mix comprising a silica matrix 8 containing a phase change material 6. The PCM/silica dry powder is shown diagrammatically only. In actual practice the phase change material is absorbed or adsorbed within and throughout the porous structure of the silica matrix. In any event the medical wrap 2 may also comprise fastener means such as "Velcro" strips (not shown) to provide for attachment of the wrap around the desired anatomical body part.
The preferred silica for use in the PCM/silica dry powder is a hydrophobic silica that has been surface treated with 0.5-5 pph (parts per hundred by weight) of a reacted silicone resin or a silane coupling agent such as dimethyldichlorosilane. As used herein in the specification and claims, hydrophobic silica is used to refer to a silica wherein the surface hydroxyl groups normally present have been reacted with silicone resins or silane coupling agents to form a less polar "hydrophobic" surface. The silica particles treated in such a manner may be either fumed silicas or precipitated silicas. Exemplary silicas include precipitated silicas such as those disclosed in U.S. Pat. Nos. 5,106,520 and 5,282,994, incorporated herein by reference. The preferred silica particle size is from about 7×10 -3 to about 7×10 -2 microns.
In FIGS. 3A-3D the liquid activating solution, such as water, for activating the endothermic or exothermic activity of the composition for thermal energy generation fills a small, sealed, liquid-tight inner bag 10 of suitable flexible plastic that is relatively easily ruptured by the liquid when squeezed manually. Inner bag 10, filed with the liquid activating solution is inserted into an open end of an open-topped intermediate envelope 11 which may be made of a liquid impervious material as in FIGS. 1, 2 and 2A. The remainder of envelope 11 is then filled or substantially filled with composition 12 of the present invention, in this instance a silica based dry powder containing an endothermic or exothermic compound for thermal energy generation. Following that, the top of intermediate envelope 11 is sealed. When the squeezing occurs, inner bag 10 is ruptured, enabling the liquid activating solution to mix with the silica based dry powder containing the endothermic or exothermic compound, causing the latter to absorb or release heat, depending on the type of material it is, but the activated mixture remains sealed in intermediate envelope 11.
After being filled, as described, and before being squeezed to absorb or release heat, the sealed intermediate envelope 11 is slidably inserted into an open-topped outer pouch 13, that is just slightly larger in size. Preferably, the outer pouch 13 is of flexible, transparent plastic, such as polyethylene or other impervious material as in FIGS. 1, 2 and 2A, and it is relatively flat, with its opposite major faces joined integrally to one another at the opposite side edges 14 and 15 and sealed to each other along the bottom of edge 16.
A thin, flat, flexible sheet 17 of heat insulation material may be inserted into the outer pouch 13 either before or after the insertion of the sealed intermediate envelope 11. This heat insulation sheet may be of fine cell or cross-linked polyethylene or other suitable material, and it extends substantially completely across the inside of one major face of the outer pouch 13 and separates this side of the pouch from the sealed intermediate envelope 11.
After both the insulation sheet 17 and the sealed inner envelope 11 have been inserted, the top of the outer pouch 13 is sealed to provide a liquid-tight package.
Preferably, the outer pouch 13 is of suitable flexible, transparent plastic and, in the absence of a defect, it does not rupture when squeezed manually. The outer pouch 13 constitutes a means for affixing the insulation sheet 17 to envelope 11. The affixing means could take other forms such as adhesive, but the outer pouch is preferred and advantageous. For example, the outer pouch provides extra protection against leakage.
Before using this instant cold or instant hot pack to either heat or cool, the pack provides a relatively flat package containing the sealed inner envelope 11 in which the particles of composition 12 are segregated from the liquid activating solution by the rupturable membrane constituted by the inner bag 10.
After the thermal energy generation upon first use, the mixture in intermediate envelope 11 may serve as a thermal energy storage device, and by heating or cooling the pack, as the case may be, it may be reused for medical therapy or other uses. Thus, the liquid activating agent may itself be a phase change material which not only activates the endothermic or exothermic compound, but is also absorbed or adsorbed by the silica particles so as to form a PCM/silica gel or dry powder capable of thermal energy storage upon reuse.
FIGS. 4 and 5 depict a tableware item, a dinner serving tray 30 of the type used by airlines, etc. that incorporates the present composition disposed therein. Tray 30 comprises a plurality of compartments 36a-d to act as receptacles for food and a beverage container. Preferably, tray 30 comprises a plastic housing 34 that is filled with composition 38 of the present invention which in one embodiment is a water/urea PCM/silica dry powder composition and in another embodiment is a silica based dry powder containing an endothermic or exothermic compound. In that instance, a tap 40 may be used for addition of a liquid activating solution such as water in order to initiate the endothermic or exothermic reaction. Alternatively, a liquid activating solution such as water may be contained in cavity 32 separated from composition 38 by a rupturable divider (not shown), such as a rupturable membrane, which is ruptured to initiate the endothermic or exothermic reaction.
As with the embodiment employing a water/urea phase change material, other uses for an instant cold system, could be for ice cream freezers and other refrigeration devices. With the instant hot system, the device would be to heat food or drink. Other uses for an instant hot system of this type would be stadium seats, boots, vests, caps, ear muffs, scarves, etc. In order that the invention may be more readily understood, reference is made to the following examples, which are intended to be illustrative of the invention, but are not intended to be limiting in scope.
EXAMPLE 1
This example illustrates the general laboratory procedure for preparing a water/urea clathrate or inclusion compound. Commercial chemical and medical grades of urea were mixed with water in ratios ranging from 90/10% water/urea by weight to 54.5/45.5% by weight. All of the samples except for the 54.5/45.5% ratio dissolved quickly at room temperature. This sample required heating to obtain a solution that did not appear to be complete when the sample cooled down to room temperature.
Analysis of thermal energy storage characteristics of the solutions was performed. The compositions containing water/urea in ratios of 30/1 down to 13/1 showed two distinct melting and freezing temperatures, one of which was essentially water, and the second apparently a clathrate or inclusion compound with a melting temperature of about -11° C. and a freezing temperature of about -15° C.
As the water content in the composition was decreased to water/urea 13/1 and lower, the melting and freezing attributed to a separate water phase disappeared altogether, and a single clathrate melting and freezing near -11° C. and -15° C. respectively remained. Further, the thermal energy storage characteristics of the water/urea phase change materials were about 70 cal/gm, which is close to the accepted value of 80 cal/gm attributed to water. Comparisons were made with water modified with ethanol at compositions of water/ethanol of 48/1 to 12/1. Such compositions exhibited normal freezing point depression and a progressively lower heat of fusion as more ethanol was added to bring the molar composition to water/ethanol 12/1.
The data regarding thermal energy storage characteristics is summarized in Tables 1, 2 and 3 wherein the differential scanning calorimetry (DSC) data includes the melting temperature in degrees centigrade (Tm° C.), the freezing temperature in degrees centigrade (Tc°C), the difference between melting and freezing temperature (Tm-Tc° C.), the heat of fusion in calories per gram (ΔHf Cal/gm) and the heat of crystallization in calories per gram (ΔHc Cal/gm).
TABLE 1______________________________________ Tm-Tc ΔHf ΔHcMaterial Tm °C. Tc °C. °C. Cal/gm Cal/gm______________________________________H.sub.2 O/EtOH -2.8 -14.2 16.2 38.8 40.195/5 wt.48.8/1 molarH.sub.2 O/EtOH -5.7 -15.3 9.6 30.6 31.590/10 wt.23/1 molarH.sub.2 O/EtOH -7.4 -16.1 8.7 27.3 27.885/15 wt.14.5/1 molarH.sub.2 O/EtOH -10.8 -21.6 10.8 22.1 22.082.5/17.512/1 molar______________________________________
TABLE 2______________________________________ Tm-Tc ΔHf ΔHcMaterial Tm °C. Tc °C. °C. Cal/gm Cal/gm______________________________________Water/Urea -11.04 -20.80 9.76 68.73 62.8690/10 wt. -3.37 -14.00 10.7230/1 molarWater/Urea -11.33 -23.49 12.15 58.39 51.9285/15 wt. -6.99 -11.51 9.6417.7/1 molarWater/Urea -11.01 -16.54 5.62 62.79 59.7680/20 wt. -14.73 3.3213.3/1 molar______________________________________
TABLE 3______________________________________ Tm-Tc ΔHf ΔHcMaterial Tm °C. Tc °C. °C. Cal/gm Cal/gm______________________________________Water/Urea -10.7 -14.8 4.1 72.5 69.078/20 wt.13.0/1 molarWater/Urea -10.8 -15.7 4.9 71.7 68.685/15 wt. -16.917.7/1 molarWater/Urea -10.71 -15.83 5.12 72.9 69.380/20 wt. -17.14 6.4313.3/1 molar______________________________________
EXAMPLE 2
Several samples of water/urea phase change material/hydrophilic silica (Cabot MS-7), i.e. PCM/silica dry powder, were prepared using the general mixing procedure described in related U.S. Pat. No. 5,282,994. The composition of the clathrate portion was varied to include water/urea ratios of 13.3/1, 13.0/1, 12.5/1 and 12.0/1. Free-flowing dry powders were formed in each case at PCM/silica compositions of 60/40% by weight. Thermal energy storage was analyzed by differential scanning calorimetry, and the data is shown in Table 4 in the same manner as the data, shown in Tables 1, 2 and 3. It was observed that all of the samples showed an undesirable low freezing temperature of about -25° C., versus about -15° C. for the 100% clathrate of the same composition. Additionally, the thermal energy storage was at a significantly lower value of 30 cal/gram, whereas the storage predicted from the value of the neat water/urea phase change material, multiplied by the percentage of phase change material in the PCM/silica dry powder should have been about 40 cal/gram. It was concluded that the hydrophilic fumed silica was bonding with some of the water and thereby destroying the stoichiometry of the water/urea phase change material.
TABLE 4______________________________________ Tm-Tc ΔHf ΔHcMaterial Tm °C. Tc °C. °C. Cal/gm Cal/gm______________________________________Water/Urea -13.7 -25.4 11.7 29.2 28.8PCM80/20 Wt.PCM/Silica 60/40Water/Urea -13.6 -28.2 13.6 26.8 26.2PCM78/20PCM/Clathrate60/40Water/Urea -13.2 -25.7 12.5 29.7 29.4PCM 75/20PCM/Silica 60/40Water/Urea -13.4 -27.2 13.8 30.6 30.4PCM 72/20PCM/Silica 60/40______________________________________
EXAMPLE 3
Using the general mixing procedure described in U.S. Patent No. 5,282,994, a sample of water/urea phase change material (10/1 molar) was mixed with PPG BXS 318 from PPG Industries of Pittsburgh, Penn. (BXS-318) hydrophobic silica (treated with 1 pph silane coupling agent) to form a PCM/silica dry powder. The silica was added to the liquid water/urea phase change material at room temperature, and a free flowing dry powder was obtained at a composition of water/urea/BXS 318 of 67/33% by weight. Thermal energy storage was determined by differential scanning calorimetry, at a heating and cooling range of 2° C./minute. In contrast to the sample of similar water/urea/silica dry powder made with Cabot MS-7, the PCM/silica dry powder made with the PPG BXS 318 had a higher freezing temperature such as would be within the capacity of the ordinary freezers, or the freezer compartment on a household refrigerator. Specific data computed from the DSC analysis were:
TABLE 5______________________________________ Tm-Tc ΔHf ΔHcMaterial Tm °C. Tc °C. °C. Cal/gm Cal/gm______________________________________Water/Urea -12.61 -17.52 4.91 39.02 37.56(10/1) BXS-318Water/Urea -12.45 -17.38 4.91 38.04 36.64(67.8/32.2)______________________________________
EXAMPLE 4
Instant cold packs, both of the prior art type, and of the type demonstrating the present invention were prepared as set forth in Table 6. Those prepared in accordance with the present invention, i.e. utilizing a silica based gel or dry powder, were prepared using hydrophilic precipitated silica particles from PPG Industries of Pittsburgh, Penn. (referred to as Silica ABS or ABS Silica) having a surface area of 150 m 2 /gram and an ultimate particle size of about 0.022 microns.
In Table 6, samples 17 and 18 show the prior art form of cold packs based on ammonium nitrate and water. Sample 18 contains seven parts of sodium chloride as a freezing point depressant. If salt were to be used, the concentration would need to be further increased (as in the commercial products) to prevent freezing to a hard lump of ice in reuse. Samples 19 and 20 both contain ABS silica sufficient to form a dry powder. Sample 20 dry powder contains additionally seven parts of NaCl freezing point depressant which is, in some respects, actually undesirable since it will make recharging by freezing, and reuse as a phase change material difficult. Accordingly, the composition of sample 19 without salt is preferred. Samples 21 and 22 of Table 6 both contain sufficient ABS silica to form a gel and the water used contains urea in the form of a water/urea (75/25) solution. This addition effectively prevents the gel from freezing to a hard ice at ordinary freezer temperatures and thus, provides reuse capability. An improved gel formulation is contained as Sample 26. In this case, the urea freezing point depressant is mixed directly into the ammonium nitrate prior to addition of the activating water. Since the urea adds further endothermic heat, this formulation may be preferred since it will go to lower temperatures and does not require any premixing of the urea with water (e.g. samples 21 and 22). The minimum temperature of Sample 26 is about 20° F. The minimum temperature for the sample 21 without the urea added to the dry powder is about 28° F.
Accordingly, this example shows endothermic compositions comprising ammonium nitrate, urea, or combinations of ammonium nitrate and urea with and without a freezing point depressant (salt or urea) and water plus sufficient hydrophilic (fumed or precipitated) silica to form a reusable gel (at lower silica concentrations) or a reusable dry powder (at higher concentrations) when activated with water.
TABLE 6______________________________________INSTANT COLD PACKS BASED ON AMMONIUMNITRATE/WATER FOR PHASECHANGE LABORATORIES Dry Dry One One Pow- Pow- Use Use der der Gel Gel Gel 17 18 19 20 21 22 26______________________________________Water (gms) 140 140 140 140 -- -- 140Water/Urea (75/25) -- -- -- -- 187 187 --gms.Urea gms. -- -- -- -- -- -- 47Silica ABS gms. -- -- 73.4 73.4 70 73.4 70Water/Silica % -- -- 65/ 65/ 72.7/ 71.9/ 72/ 35 35 27.3 28.1 28NH.sub.4 NO.sub.3 gms. 168.sup.(1) 168.sup.(1) 168.sup.(2) 168.sup.(2) 168.sup.(2) 168.sup.(2) 168.sup.(2)Salt (gms) -- 7 -- 7 -- -- --______________________________________ .sup.(1) Ammonium Nitrate Prills (Pellets) .sup.(2) Ammonium Nitrate Powder
EXAMPLE 5
Instant hot packs demonstrating the present invention were made as set forth in Table 7. The Silica ABS is the same as that discussed in Example 4.
The two hot packs include duplicates of a gel (No. 21) and dry powder (No. 23) respectively based on calcium chloride and ABS silica with water to activate. The gels give a higher maximum temperature, but the dry powders have better conformability. Maximum temperatures in the range of 155° to 145° F. were recorded for the gel and dry powder respectively.
Accordingly, this example shows a chemical composition for "instant hot" applications comprised of a high exothermic molal heat of solution compound having a relatively low molecular weight, a high solubility in water, plus hydrophilic silica in an amount sufficient to form a gel or a dry powder when subsequently mixed with separately contained water in ratios determined by the solubility of the exothermic compound in water.
TABLE 7______________________________________INSTANT HOT PACK BASED ON CALCIUMCHLORIDE/WATER/SILICASample Number (21) (23)Sample Type Hot Pack Hot Pack(Gel or Dry Powder) Gel Dry Powder______________________________________1. Water, distilled (gms) 200 2002. Ammonium Nitrate (gms)3. Calcium Chloride (gms) 119 1194. Silica ABS (gms) 53 98.55. Water/Silica (%) 79/21 67/336. Min. or Max. Temp. °F. 155 147______________________________________
The primary advantage is that the instant cold or instant hot reaction can be initiated by mixing with water anytime, anyplace, and the need for "charging" by prefreezing the instant cold or microwave heating the instant hot system is eliminated altogether. The primary disadvantage of the instant hot and instant cold gels and dry powders is that they cannot supply cold or heat for as long a time period as the comparable phase change materials, and the instant cold or hot is provided on a thermocline of ascending or descending temperature--not on a plateau of constant temperature as in the comparable phase change materials.
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 methods and apparatus disclosed herein may be made without departing from the scope of the invention, which is defined in the appended claims. | A composition for thermal energy storage or thermal energy generation comprising a silica based gel or dry powder in the form of silica particles containing a water/urea phase change material for thermal energy storage or an endothermic or exothermic compound for thermal energy generation. The water/urea phase change material stores and releases at least 50 cal/gm of thermal energy in freezing and melting, and has a melting and a freezing point in the range of -11° C. to -15° C. The endothermic compound is preferably ammonium nitrate, urea, or combinations thereof. The exothermic compound is preferably calcium oxide or calcium chloride. The thermal energy storage composition may find use in a variety of applications including medical wraps, food servingware, and "blue ice" for cold packs or food storage. The thermal energy generation composition may find use as medical wraps, food servingware, and refrigerators when endothermic and medical wraps, food servingware, heaters, stadium seats, boots, vests, caps ear muffs, and scarves when exothermic. | 5 |
FIELD OF THE INVENTION
The present invention relates to an apparatus and a method for analyzing body composition based on bioelectrical impedance analysis (BIA). More particularly, the present invention relates to an apparatus and a method for analyzing body composition using a hand electrode apparatus for improving the precision in measuring the upper body impedance by passing a weak, alternating current across the body through the current electrodes and reading the voltage difference.
BACKGROUND OF THE INVENTION
A human body is composed of water, protein, bone, and fat, in addition to a small amount of special components. The total of these elements constitutes the body weight. Quantitatively measuring the respective elements is called body composition analysis. Recent years body composition analyzers have been actively developed due to interest in health care from fatness. The proportion occupied by the fat is called fatness and is used in diagnosing various adult diseases. Especially, the water portion is the main component for supporting the human body and the amount thereof is related to the amount of muscle generating energies. Thus, the amount of muscle in body is applied widely as an index indicating nutritive conditions. In the medical terms, patients suffering from malnutrition related, for example, to cancer are subjected to a periodically measuring the amount of muscle in body to determine remission state or to monitor progress of the disease. Further, the growth in child body and the nutrition status of elderly men can be diagnosed on basis of the analysis of the amount of muscle. Accordingly, an analysis of the body composition has been used as basic means to examine a person and needs for the precision in measuring the body composition have been increased. As one of conventional methods for measuring the body composition, bioelectrical impedance analysis (BIA) is widely employed. This method has advantages such as safety, fastness, and low cost in comparison with the other conventional methods. This method is carried out the following manner. That is, a weak alternating current is passed across the human body to analyze the body composition by measuring the electrical resistance or the impedance of the body.
A basic principle to measure the body composition by using BIA, is as follows: where rich in water, a weak alternating current flows easily so that a low resistance value is obtained. While, where insufficient in water the current is difficult to flow so that a high resistance value is obtained. As muscle contains the most water in the body, each amount of muscle and body fat may be measured on the above-mentioned principle. The apparatus for analyzing the human composition substitutes body height, weight, age, gender, and measured impedance of the human subject into the specific expression to calculate the body composition, and displays the analyzed results on the LCD display unit.
FIG. 1 shows the conventional embodiment of determining the upper body composition by measuring the impedance between both hands. As shown In FIG. 1 ( a ), a person in an upright posture grasps a pair of electrodes comprising a left electrode and a right electrode, with arms stretched to the front. In the embodiment, upper palm electrodes 5 , 7 contact with the upper part of a palm and fingers, and lower palm electrodes 6 , 8 contact with the lower part of a palm and fingers, and the human subject locates the center of hands on the boundary between the upper hand electrode and the lower hand electrode to contact with the current electrode and the voltage electrode. As shown in FIG. 1 ( c ), the electrodes contact with the palm and the fingers to be connected electrically with the body. However, the method has the disadvantage that the variation in the contact location between the electrode and the body depends on the grip posture and the change of contact area between the electrode and the body depends on the grip intensity, resulting in a low reproducibility of the measurement.
FIG. 2 represents another embodiment of determining the upper body composition by measuring the impedance between the right and left hand. The human subject grasps a column-shaped current electrode on the right and left side of the apparatus and contacts the right and left wrist on a voltage measuring electrode. The apparatus passes the electric current across the body through the column-shaped electrode and reads voltage differences between wrist electrodes used as the voltage electrodes. However, some variations in the contact location and the contact region are inevitable even for the same person, which results in a low reproducibility of the measurement. Further, the individual difference in the body size, for example the difference in arm length between an adult and a child, raises the deviation of the contact location.
In the prior arts, the accuracy and reproducibility of measurement highly count on how to grip the electrodes when the measurement is carried out for the untrained person. Thus, variations in contact location and contact region are inevitable and affect the measured value.
The present inventor developed an apparatus for analyzing body composition based on bioelectrical impedance analysis, which is disclosed in U.S. Pat. No, 5,720,296 and Korean patent No. 123,408 and No. 161,602. The inventions improve the accuracy in analyzing the body composition and can measure segmental impedances by using an electronic switch which is controlled by a micro-processor. However, the apparatus has disadvantages in portability.
Thus, in the method measuring the impedance between two arms by measuring the voltage difference between the voltage electrodes, the present inventor has invented an apparatus for analyzing body composition, which can improve the precision by minimizing factors to affect measurement results, when measurement is carried out repeatedly for individuals or the same person without a specially trained examiner.
OBJECTS OF THE INVENTION
An object of the present invention is to provide an apparatus for analyzing upper body composition, in which the upper body composition can be analyzed conveniently by passing an electric current across the body through the current electrodes and measuring the impedance between voltage electrodes.
Another object of the present invention is to provide an apparatus for measuring the upper body composition in which if palm electrodes are used as a current electrode, then thumb electrodes are used as a voltage electrode, and if thumb electrodes are used as a current electrode, then palm electrodes are used as a voltage electrode, so as to improve accuracy and reproducibility in the measurement.
A further object of the present invention is to provide a simple and portable apparatus for measuring the body composition which uses only hand electrodes to measure the upper body impedance.
A further object of the present invention is to apply the electrode method, in which a measuring person grips column electrode and contacts his thumbs to thumb electrodes, to other apparatuses measuring the upper body impedances.
The above objects and other advantages of the present invention will be apparent from the ensuing disclosure and appended claims.
SUMMARY OF THE INVENTION
A handle-shaped apparatus for analyzing the body composition based on the bioelectrical impedance analysis according to the present invention comprises: a right palm electrode 1 and a left palm electrode 3 located on the right and left side of said apparatus, contacting with each inner surface of the right and left palm and fingers excluding a thumb; a right thumb electrode 2 and a left thumb electrode 4 located by the side of said palm electrodes, so that a measuring person can grasp said palm electrodes and contact said thumb electrodes with the right and left thumbs; an impedance measuring circuit 15 for measuring the impedance based on a voltage-current ratio by making an alternating current flow between two of the electrodes with a current generator 13 therein and reading the voltage difference with a voltage meter 14 therein; an amplifier 16 and A/D converter 17 for interfacing the impedance measuring circuit 15 , to a microprocessor; a keyboard 18 to input the body height, weight, gender, and age; the microprocessor 19 processing the data received from the impedance measuring circuit 15 and the keyboard 18 ; and a display unit 20 for to display the results processed by the microprocessor 19 , thereby the apparatus locates voltage electrodes outside of the current pathway to measure the upper body impedances, highly reproducibly irrespective of the grip posture and grip intensity. In the body composition analyzing apparatus of the present invention, the results processed by the microprocessor are shown on the display.
The apparatus of this invention may be equipped with an interface for connecting an outside computer.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 ( a ) is a schematic view showing the conventional embodiment for measuring the upper body impedances;
FIG. 1 ( b ) is a plane figure of the conventional apparatus for measuring the upper body impedances;
FIG. 1 ( c ) illustrates hand regions contacting with the conventional apparatus for measuring the upper body impedances;
FIG. 2 ( a ) is a schematic view showing an embodiment for measuring the upper body impedances using another conventional measuring method;
FIG. 2 ( b ) is a plane figure of another conventional apparatus for measuring the upper body impedances;
FIG. 2 ( c ) illustrates hand regions contacting with another conventional apparatus for measuring the upper body impedances;
FIG. 3 ( a ) is a schematic view showing an embodiment for measuring the upper body impedances using the hand electrode method according to the present invention;
FIG. 3 ( b ) is a plane figure of the apparatus for measuring the upper body impedances according to the present invention;
FIG. 3 ( c ) illustrates hand regions contacting with the apparatus for measuring the upper body impedances according to the present invention;
FIG. 4 schematically illustrates an impedance model of a human body to be measured by the apparatus according to the present invention;
FIG. 5 is an electric circuit illustrating schematically the principle measuring the upper body impedances according to the present invention; and
FIG. 6 illustrates the circuit of the body composition analyzing apparatus according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Reference will now be made to the drawings wherein like structures will be provided with like reference designations.
FIG. 3 is a schematic view showing an embodiment for measuring the upper body impedances using the hand electrode method according to the present invention.
A body composition analyzer of this invention comprises: a right palm electrode 1 located on the right side of the apparatus, contacting with inner surfaces of the right palm and fingers excluding a thumb; a right thumb electrode 2 for contacting with only a right thumb; a left palm electrode 3 located on the left side of the apparatus, contacting with inner surfaces of the left palm and fingers excluding a thumb; and a left thumb electrode 4 for contacting with only a left thumb. Thus, the body composition analyzing apparatus according to the present invention is in a handle shape, wherein the right and left sides are used as palm electrodes and the thumb electrodes are located by the side of the palm electrodes, so that a human subject may grip palm electrodes and press the thumbs on the thumb electrodes. A measuring person stretches arms to the front in a standing posture and an electric current flows into the body through the palm electrodes used as current electrodes so that the impedance is measured by reading the voltage difference between the thumb electrodes used as voltage electrodes.
Each of the electrodes 1 - 4 serves as a current electrode or a voltage electrode. If the electrodes 1 , 3 are used as current electrodes, then the electrodes 2 , 4 are used as voltage electrodes. On the other hand, if the electrodes 2 , 4 are used as current electrodes, then the electrodes 1 , 3 are used as voltage electrodes, which can be conducted by a person with ordinary skills in the art.
FIG. 4 schematically illustrates an impedance model of a human body to be measured by the apparatus according to the present invention.
It will be indicated as follows:
The resistance from the right wrist to the left wrist is indicated by R a , the resistance from the right wrist to the right thumb is indicated by R rt , the resistance from the left wrist to the left thumb is indicated by R lt , the resistance from the right wrist to the right palm is indicated by R rp , and the resistance from the left wrist to the left palm is indicated by R lp .
FIG. 5 is an electric circuit illustrating schematically the principle measuring the upper body impedances according to the present invention.
The electric current flows in order of R rp , R a , and R lp in the body through two palm electrodes. The measured voltage difference between the thumb electrodes means the voltage difference between both ends of R a , the impedance values of the portion where the electric current flows. At this moment, the measured values are not affected by R rp , R lp , R rt , and R lt .
The above-mentioned principle has important meanings in view of the technique. When a person grips the electrodes, the variation of contact location between the body and the electrodes depends significantly on the grip. In the conventional method, said variations in contact location have a direct effect on the measured results. Therefore, the determined values are changeable for each test. On the contrary, according to this invention the variations of R rt , R lt , R rp , and R lp have no influence on R a , which is the upper body resistance. Therefore, this method is highly evaluated as it can improve the measurement precision.
FIG. 6 illustrates the circuit of the body composition analyzing apparatus according to the present invention.
The current generator 13 in the impedance measuring circuit 15 for measuring the impedance makes an alternating current flow at the frequency of between 1 kHz and 1000 kHz and flows the current into the body, and the voltage meter 14 reads the voltage difference between two voltage electrodes. The signals measured by the impedance measuring circuit 15 are transferred to the microprocessor 19 through the amplifier 16 and the A/D converter 17 . The weight, body height, age and gender of the measuring person are inputted through a keyboard and are processed along with the data received from the impedance measuring circuit by the microprocessor 19 , which controls the storage, calculation, and output of the data. The results of the analysis can be shown on the display unit 20 .
The apparatus of this invention may be equipped with an interface 21 for connecting outside computers for further calculation and storage of the data.
Examples for computing the body composition from the measured impedances, body height, weight and gender are as follows.
The amount of water contained in the body is proportional to Ht 2 /R, wherein R is the impedance or the resistance and Ht is the height of the measuring person.
The total body water (TBW) in the body is defined as follows:
TBW=C 1 Ht 2 /R a +C 2 Wt+C 3 GENDER+C 4 AGE+C 5 (I)
wherein C 1 , C 2 , C 3 , C 4 , and C 5 are the best suitable constants, Ht, Wt, GENDER, AGE are respectively, the height, weight, gender, and age of the measuring person.
Equation (I) is stored in the microprocessor, and therefore, TBW can be obtained from the measured impedances and the input data.
Body fat contains relatively small amount of water, and therefore, this water content is disregarded. The fat free mass (FFM) contains about 73% of water, therefore FFM is defined as follows:
FFM=TBW/0.73 (II)
The amount of body fat (FAT) is defined to be the weight (Wt) minus FFM, and is defined by Equation (III), thus percent body fat (% BF) is defined by Equation (IV) as follows:
FAT=Wt−FFM (III)
% BF=(Wt−FFM)×100/Wt (IV)
The following example is given to illustrate the present invention and not intended as limitation thereof. Values in the table are in Ω unless otherwise specified.
EXAMPLE
This Example is carried out for five human subjects by means of the method as shown in FIG. 3 . The resistances were measured repeatedly five times per each subject with the grip varied per each test. An alternating current in the magnitude of 800 mA at the frequency of 50 kHz flows into the body and the resistances were measured with BIA-101A model of RJL system Co. The test results are as set forth in Table 1, below:
TABLE 1
Subjects
Run
1
2
3
4
5
1
633.0
653.0
1016.0
767.0
581.0
2
628.0
648.0
1020.0
754.0
578.0
3
638.0
663.0
1024.0
761.0
587.0
4
629.0
651.0
1020.0
755.0
586.0
5
624.0
655.0
1018.0
756.0
584.0
Average
629.4
654.0
1019.6
758.6
583.2
The standard
3.8
5.7
3.0
5.4
3.7
deviation
The above results show that though different resistances are obtained for each of the subjects, the reproducible results for one person are obtained irrespective of the grip posture.
COMPARATIVE EXAMPLES
Comparative Examples 1˜2 were carried out in the same manner as the Example except that the conventional electrode method were applied. The test results are presented in Table 2˜3.
TABLE 2
Subjects
Run
1
2
3
4
5
1
681.0
689.0
1086.0
807.0
628.0
2
662.0
642.0
1120.0
824.0
660.0
3
679.0
679.0
993.0
782.0
618.0
4
657.0
660.0
986.0
756.0
637.0
5
651.0
699.0
1060.0
821.0
610.0
Average
660.0
673.8
1049.0
798.0
630.6
The standard
13.4
22.9
58.4
28.7
19.3
deviation
TABLE 3
Subjects
Run
1
2
3
4
5
1
429.0
443.0
731.0
489.0
416.0
2
489.0
426.0
770.0
555.0
492.0
3
468.0
463.0
677.0
459.0
500.0
4
415.0
477.0
842.0
413.0
414.0
5
449.0
418.0
817.0
529.0
446.0
Average
450.0
445.4
767.4
489.0
453.6
The standard
29.6
24.7
66.2
56.2
40.8
deviation
When the test is carried out with the grip varied, the test results according to the conventional methods show the large standard deviations. That is to say, the grip posture and the grip intensity cause the contact location to vary inevitably, which has significant effects on the test results. While the test results measured according to this invention show the small standard deviations. As a result of analyzing the anatomical structure and of contemplating the contact location between the electrode and the body, the apparatus according to this invention locates voltage electrodes outside of the current pathway to measure the upper body impedances highly reproducibly irrespective of the grip posture and grip intensity.
It should be apparent to those skilled in the art that various changes and modifications can be added to the present invention without departing from the scope of the present invention, which is limited only by the appended claims. | The present invention relates to an apparatus and a method for analyzing body composition using a hand electrode apparatus for improving the precision in measuring the upper body impedance by passing a weak, alternating current across the body through the current electrodes and reading the voltage difference. The voltage electrodes are located outside the current pathway to give a more accurate measurement of body impedance. | 0 |
CROSS-REFERENCE TO RELATED APPLICATION
This application claims the priority of German Application No. 197 29 145.7 filed Jul. 8, 1997 which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
This invention relates to a flat-stock, stamped knitting tool for textile machines, particularly knitting and warp-knitting machines. The knitting tool includes a shank, having at least one free space (hereafter "window opening") formed therein by shank edges having at least one region of reduced shank thickness. The window opening is filled with a heterogeneous material which is firmly connected to the shank and which projects into the region of reduced shank thickness.
By the term "knitting tool" latch needles, springbeard needles, compound needles, latchless needles such as plush hooks for producing plush material, as well as sinkers and the like are meant.
As explained in detail, for example, in U.S. Pat. No. 5,582,038 based on the prior art mentioned therein, stamped knitting tools are known that have at least one window opening formed in the shank, for example, in the shape of an elongated hole, whose longitudinal axis is parallel to or coincides with the longitudinal axis of the shank. The window opening is filled with a vibration-damping, heterogeneous material which is firmly connected to the needle shank. As a rule, the material is a flexible plastic having high damping characteristics, although other materials may be used instead.
The vibration behavior of the knitting tool is favorably influenced by the vibrating-damping material disposed in the window opening of the shank. It is feasible to divide the knitting tool into a highly elastic structure in which the longitudinal hole is delimited by two continuous vertical guide portions extending from the upper shank edge to the lower shank edge, and two narrow webs interconnecting the guide portions. The webs are arranged parallel to each other and have often a web height of no more than 1.1 mm. Such knitting tools may be used over long operational periods with high operational speeds, without the occurrence of an appreciable number of web or hook breakages due to material fatigue. Due to the fact that the window openings are filled-in and are thus not open, no lint or dirt deposits can collect therein which, depending on the operating conditions, is considered an advantage.
Since the vibration-damping material that fills the window opening can be effective only if it is firmly connected to the shank material along the edge of the window opening, additional measures have been previously taken to provide a form-locking anchoring of the plastic material, particularly for very thin knitting tools, which in operation are exposed to bending due to lateral forces in the region of the window opening. In this connection published European Application 282 647 discloses the profiling of the web and/or guide element regions that surround the window opening. The profiling can have zones of reduced wall thickness, which are either locally limited or which extend in a strip-like manner over the entire periphery of the window opening or a portion thereof. The zones of reduced wall thickness project into the plastic material which fills the window opening and contribute to a form-locking anchoring of the plastic material to the tool shank.
To facilitate the manufacture of knitting tools of the above-outlined type, particularly knitting needles with window openings having profiled regions of reduced shank thickness around the periphery of the window opening, the earlier-noted U.S. Pat. No. 5,582,038 discloses that the shank is, at least section-wise along the edge of the window opening, chamfered inwardly towards the window opening such that the chamfered regions project into the heterogeneous material that fills the window opening. The chamfered regions are, as a rule, embossed into the shank and are arranged on both sides of the shank.
It has been found in practice that embossing chamfered edges which, as viewed cross-sectionally, taper in a wedge-like manner towards the window opening, may involve difficulties in certain needle types. This is due to the fact that during the embossing of the edge region of the punched-out window opening, shank material is displaced outwardly from the window opening, thus resulting in an uneven material accumulation in the shank material that surrounds the embossed region. This, in turn, leads to undesirable configurational changes in the subsequently stamped-out knitting tool. This is so because, as a rule, when stamping such a knitting tool, the window openings are punched out first from a flat-steel ribbon and are subsequently embossed along the edge of the window opening, and thereafter the knitting tool itself is stamped out. If, in the course of the stamping operation the knitting tool, because of the preceding embossing operation, undergoes a lasting configurational change, for example, a change where the shank height in the region of the punched-out window opening is increased slightly relative to the stamping dimensions as the internal stress conditions are equalized, then complex reworking operations may be necessary.
SUMMARY OF THE INVENTION
It is an object of the invention to remedy the above-outlined problem and to provide an improved knitting tool which has a high degree of dimensional accuracy and which is simple to manufacture while providing a flawless, form-locking anchoring of the heterogeneous material which fills the shank window opening.
This object and others to become apparent as the specification progresses, are accomplished by the invention, according which, briefly stated, the stamped knitting tool includes a shank having a shank thickness; and a window opening provided in the shank and defined by shank edges of the shank. The shank edges have an edge region of reduced thickness relative to the shank thickness. The edge region of reduced thickness has an increasing thickness as viewed in cross section in a direction toward the window opening. The edge region of reduced thickness has a minimum thickness and a maximum thickness; the maximum thickness is closer to the window opening than the minimum thickness and is less than the shank thickness. A heterogeneous material fills the window opening and is firmly connected with the shank, and the edge region of reduced thickness projects into the heterogeneous material.
While the cross section of the edge region of reduced shank thickness has, as a rule, an at least approximately trapezoid shape, it may have other configurations as well. The edge region of reduced shank thickness is advantageously embossed into the shank; the edge region may have a toothed profile at least in sections.
By forming the edge region of reduced shank thickness as a "negative puncture", during the embossing operation the appearance of force components tending to enlarge the window opening is prevented. The shank material plastically displaced during the embossing operation creeps harmlessly in the direction of the window opening.
An improvement in the anchoring of the generally synthetic, heterogeneous material in the window opening may be achieved by shaping the edge region of reduced shank thickness to have at least sectionally a toothed profile, as noted earlier. The provision of such holding teeth ensures that the plastic filler material is held in place optimally in the longitudinal direction of the shank even if the material shrinks within the knitting tool.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic side elevational view of a latch needle incorporating the invention.
FIG. 2 is a top plan view of the latch needle shown in FIG. 1.
FIG. 3 is a fragmentary enlarged side elevational view of the latch needle of FIG. 1 in the region of an unfilled window opening provided in the shank thereof.
FIG. 4 is an enlarged sectional view taken along line IV--IV of FIG. 3, with simultaneous illustration of the embossing tool.
FIG. 5 is a fragmentary sectional view taken along line IV--IV of FIG. 3 on a scale enlarged relative to FIG. 4, to illustrate the actual profiled configuration resulting from the embossing operation.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The latch needle shown in FIGS. 1 and 2 has a needle shank 1, conventionally punched out of a steel strip, two butts 2 that are formed on the upper shank edge 11 and a needle head 3 which is arranged at one end of the shank 1 and which has a needle hook 4. A needle latch 5 cooperates with the needle hook 4. In the illustrated embodiment throughgoing, longitudinally spaced elongated holes 6 are punched into the needle shank 1. Each hole 6 forms a window opening that is filled with a heterogeneous material 8 which is firmly connected to the shank 1 along the edge of each elongated hole 6. As a rule, the material is a plastic, preferably a polyamide-12, polyurethane, polyethylene, polytetrafluoroethylene or the like, but may instead be an inorganic material, such as a metal.
Each window opening 6 is delimited along its longitudinal sides by two parallel webs 9, 10 and at its opposite ends by two guide parts 13 that extend continuously from the upper shank edge 11 to the lower shank edge 12. Underneath each butt 2 a guide part 13 is situated. The two webs 9 and 10 positioned along the upper shank edge 11 and the lower shank edge 12, respectively, have a small height of about 1.1 mm or less. Advantageously, the length of the webs 9 and 10 is more than 8 mm. It is to be understood, however, that the invention is not limited to knitting tools having such dimensions.
In the illustrated embodiment the contour of each window opening 6 is delimited along the longitudinal sides adjacent to the two webs 9, 10 by essentially two straight edges 14, 15 which are connected to each other at the opposite ends of the window opening by two approximately elliptical edges 16, 17.
As shown in FIG. 3, the essentially straight edges 14, 15 are each interrupted by three spaced holding teeth 19 which project into the space formed by the window opening 6 and which have a width 19' measured parallel to the length of the window opening. The projecting contour of the teeth 19 joins the straight edges 14, 15 by means of rounded portions 18.
In the region of the two webs 9, 10 the shank 1 is provided on both sides, along the edge of each window opening 6, with a narrow, strip-like edge zone 20 which has a reduced shank thickness. As seen particularly in FIGS. 4 and 5, the edge zone 20 of reduced shank thickness has a cross-sectional form of increasing thickness, starting with a region 21 of minimum thickness at its root and widening in the direction toward the window opening 6 to a region 22 of maximum thickness. An imaginary plane 23 containing a side of the cross-sectionally trapezoidal edge region 20 forms a chamfer angle 24 of approximately 10° with the adjoining surface of the shank side. The size of the chamfer angle 24 of the "negative puncture" formed thus by the edge region 20 depends on the requirements and the geometric data of the knitting tool. As a rule, the chamfer angle 24 is in the range of approximately 5° to 60°.
For the embodiment shown, the minimum thickness at 21 of the edge region 20 amounts to approximately 60% of the shank thickness 26 as illustrated in FIG. 5. In practice a minimum thickness range of approximately 20 to 80% or more of the shank thickness 26 has proven useful, depending on the properties of the knitting tool.
In the described embodiment of FIG. 5, the maximum thickness at 22 of the edge region 20 is approximately 70% of the shank thickness 26. Depending on the geometric and operational data of the knitting tool, the maximum thickness 22 is preferably between approximately 40% and 95% of the shank thickness 26. The maximum thickness 22 is, however, always less than the shank thickness 26, so that a secure anchoring of the plastic filler material 8 remains ensured along the edge regions 20. FIG. 5 shows that the edge regions 20 of reduced thickness project into the plastic filler material 8, in which they are embedded, while the projecting holding teeth 19 serve as an additional form-locking anchoring.
The edge regions 20 of reduced shank thickness are provided in the needle shank 1 by embossing as part of the manufacturing process for making the latch needle.
First the window openings 6 having a contour including the holding teeth 19 are punched out from the flat-steel blank. As previously explained, such a contour is composed of the essentially straight lines (edges) 14 and 15 and the projecting holding teeth 19 along two opposite longitudinal window opening sides and by essentially elliptical lines (edges) which connect the two straight lines 14, 15 at opposite longitudinal ends of the window openings 6.
Thereafter the edge regions 20 of reduced shank thickness are embossed into the shank 1 on both shank sides. Such an operation is effected by an embossing tool which is shown in cross section in FIG. 4 and which comprises a die plate 29 and an embossing stamp 30 cooperating with the die plate 29. The die plate 29 and the embossing stamp 30 have respective embossing faces 29a or 30a oriented to one another. Each face 29a and 30a is formed of two planar surfaces inclined to one another in a flat "V"-shaped configuration under an obtuse angle 31 which determines the desired chamfer angle 24 shown in FIG. 5.
The axial length of the die plate 29 and the embossing stamp 30 is shorter than the length of the associated window opening 6. The embossing stamp 30 extends in the longitudinal direction only between the two semicircular arcs 28 shown in FIG. 3 in broken lines. It is a result of such an arrangement that the regions 20 of reduced shank thickness embossed into the shank 1 extend only along the facing longitudinal sides of the window opening 6, between the two broken delimiting lines 32 situated approximately at a location where the holding teeth 19 disposed at the longitudinal ends of the window opening 6 change into the elliptical terminal window opening edges 16 and 17.
When embossing the regions 20 of reduced shank thickness, the embossing surfaces 29a, 30a of die plate 29 and the embossing stamp 30 penetrate into the shank material, starting at the radially outer edge of the regions 20. Since the embossing surfaces 29a and 30a are inclined in a rearwardly receding manner, the embossing forces have components that are oriented toward each other and are inclined toward the window opening 6. Such component forces tend to push the plastically deformed material toward the window opening, whereby an enlargement of the window opening 6 and an inherent irregular deformation of webs 9, 10 are avoided. Such a material displacement into the window opening in the direction of the window opening 6 is visible in FIG. 5 as a pinch formation in the front face 33 which is composed of two partial surfaces convexly curved from the edge inwardly and meeting approximately in the longitudinal symmetry plane for shank 1.
Upon completion of the embossing operation, the latch needle blank is stamped from the strip steel and is advanced for further processing, during the course of which the plastic filler material 8 is inserted into the window openings 6. Since the regions 20 of reduced wall thickness do not extend past the elliptical arcs 28 at the ends of the window openings 6, the plastic material is not connected in a form-locking manner with the shank 1 on at such locations. Such an arrangement has proven to be useful particularly for ends of the window opening oriented toward a butt 2.
The width of one of the regions 20 of reduced shank thickness measured perpendicularly to the longitudinal shank axis 34 typically amounts to approximately 0.1 to 0.5 mm and is preferably approximately 0.2 mm.
For the embodiment shown, the window openings 6 in the shank 1 are elongated holes. It is to be understood, however, that the invention also encompasses window openings of any desired contour corresponding to the desired purpose. Also, the window openings are not limited to the illustrated closed outline; they may be edge-wise open cutouts provided in the shank 1.
It will be understood that the above description of the present invention is susceptible to various modifications, changes and adaptations, and the same are intended to be comprehended within the meaning and range of equivalents of the appended claims. | A stamped knitting tool includes a shank having a shank thickness; and a window opening provided in the shank and defined by shank edges of the shank. At least one of the shank edges has an edge region of reduced thickness relative to the shank thickness. The edge region of reduced thickness has an increasing thickness as viewed in cross section in a direction toward the window opening. The edge region of reduced thickness has a minimum thickness and a maximum thickness; the maximum thickness is closer to the window opening than the minimum thickness and is less than the shank thickness. A heterogeneous material fills the window opening and is firmly connected with the shank, and the edge region of reduced thickness projects into the heterogeneous material. | 3 |
FIELD OF THE INVENTION
This invention relates to a novel method of preparing cyano-keto-acids from the stoichiometric condensation of substituted phenylacetonitriles with dibasic carboxylic anhydrides.
BACKGROUND OF THE INVENTION
Certain 2-aryl-1,3-cyclohexanediones and their esters are known to be extremely active, biological compounds. U.S. Pat. Nos. 4,175,135 and 4,256,657 and copending application U.S. Ser. No. 781,781 filed Mar. 28, 1977, all of which are herein incorporated by reference, teach the usefulness of these compounds as herbicidal and miticidal agents and as agents for orally controlling acarina ectoparasites on warm-blooded animals.
Cyano-keto-acids, such as the 6-aryl-6-cyano-5-keto-hexanoic acids and/or their esters are important intermediates in the manufacture of the afore-described 2-aryl-1,3-cyclohexanediones.
U.S. Pat. No. 4,256,657 teaches that the coupling of ring-substituted phenylacetonitriles with alkyl-substituted glutaric acid derivatives in a basic reaction medium will result in esters of the cyano-keto-acids described above, e.g. Example XVI of said patent. However, a significant disadvantage to this process is the large molar excess (50 to 200%) of glutaric acid derivative required to suppress reaction of a second molecule of ring-substituted phenylacetonitrile with the desired product.
SUMMARY OF THE INVENTION
In accordance with the present invention, it has been discovered that good yields of cyano-keto-acids can be realized by the stoichiometric coupling of ring-substituted phenylacetonitriles with substituted glutaric anhydride. Furthermore, the resulting substituted hexanoic acid may be incorporated directly into the prior art process of U.S. Pat. No. 4,175,135 for the production of 2-aryl-1,3-cycylohexanediones.
DETAILED DESCRIPTION OF THE INVENTION
The invention relates to the discovery that ring-substituted phenylacetonitriles can be stoichometrically coupled with substituted glutaric anhydrides to produce cyano-keto-hexanoic acids in good yields.
Specifically, the invention relates to the discovery that compounds of the formula ##STR1## can be prepared in good yield by reacting a phenylacetonitrile of the formula: ##STR2## wherein Z, Z', Z" and Z'" are individually hydrogen, nitro, polyhaloalkyl, halogen, cyano, alkyl, alkoxy, alkylthio, alkylsulfinyl, alkylsulfonyl, alkanoyl, amido, amino, or haloalkyl; and R 1 is alkyl, halogen, polyhaloalkyl, or haloalkyl;
with a stoichiometric amount of a compound of the formula: ##STR3## wherein R 2 , R 3 , R 4 , R 5 , R 6 and R 7 are individually hydrogen or either substituted or unsubstituted alkyl or phenyl wherein the permissible substituents are one or more alkyl, cyano, halogen, nitro, alkoxy, alkylthio, alkylsulfinyl, alkylsulfonyl, or dialkylamino substituents or any two R 2 , R 3 , R 4 , R 5 , R 6 or R 7 substituents together may form an alkylene or alkenylene chain having from 2 to 20 carbon atoms completing a 3, 4, 5, 6 or 7 membered ring structure;
with the proviso that R 1 , R 2 , R 3 , R 4 , R 5 , R 6 , R 7 , Z, Z', Z" and Z'" substituents individually may not include more than ten aliphatic carbon atoms; in the presence of a base and a non-protic solvent at a temperature of from about 60° C. to about 150° C.
Although the temperature and pressure of the process are not critical, it is preferred to operate at from about 100° C. to about 140° C. and most preferably from about 120° C. to about 135° C. at atmospheric pressure.
Preferred substituents in the reactions of this invention, primarily because of the high miticidal effects realized in the 2-substituted-1,3-cyclohexanediones derived from the intermediates of this invention, are the following:
Z, Z', Z" and Z'" are individually hydrogen, alkyl, cyano, alkoxy, halogen, or trihalomethyl;
R 1 is alkyl or halogen; and R 2 , R 3 , R 4 , R 5 , R 6 and R 7 are individually hydrogen or alkyl.
The most preferred substituents are the following:
Z, Z', Z" and Z'" are individually hydrogen, methyl, methoxy, cyano, or halogen;
R 1 is methyl or halogen; and R 2 , R 3 , R 4 , R 5 , R 6 and R 7 are individually hydrogen, methyl or ethyl.
Illustrative of the strong bases which are useful in the reactions of this invention are the metal alcoxides, alkali metal amides, alkali metal hydrides or mixtures of these bases.
The preferred base is sodium ethoxide.
It is also preferred that at least two equivalents of base be present during the reaction.
Illustrative of the non-protic solvents which are useful in this invention are the aromatic hydrocarbons, cyclic and acylic ethers, dimethyl sulfoxide, dimethylformamide, and sulfolane. The preferred non-protic solvents are dimethoxyethane, tetrahydrofuran, n-butyl ether, dioxane and xylene.
The following examples are set forth for purposes of illustration so that those skilled in the art may better understand the invention, and it should be understood that they are not to be construed as limiting this invention in any manner.
EXAMPLE I
Preparation of 6-cyano-3,3-dimethyl-5-keto-6-(2-methylphenyl)hexanoic acid (METHOD I)
To a suspension of a sodium amide-sodium t-butoxide complex, prepared by adding 9.5 g of t-butanol in 25 ml of dry tetrahydrofuran to 10 g of sodium amide in 50 ml dry tetrahydrofuran and purging with N 2 for 15 minutes, was added at 0° C. a solution of 13.1 g 2-methylphenylacetonitrile in 25 ml tetrahydrofuran. The solution was held at 0° C. for 30 minutes while flushing the reaction system with N 2 to remove the ammonia liberated. A solution of 14.2 g 3,3-dimethylglutaric anhydride dissolved in 75 ml tetrahydrofuran was added as rapidly as possible and the solution heated to reflux for 5 hours. The reaction mixture was cooled to 40° C. and quenched with 150 ml. water. The organic layer was separated, diluted with 75 ml ethyl ether, and extracted with 100 ml water. The combined aqueous layers were extracted once with 75 ml ethyl ether, then acidified to pH 2 with concentrated hydrochloric acid. The aqueous solution was extracted three times with 75 ml of methylene chloride and the combined methylene chloride extracts dried over magnesium sulfate. Stripping the solvent at reduced pressure produced a residue containing 16.42 g of 6-cyano-3,3-dimethyl-5-keto-6-(2-methylphenyl)hexanoic acid.
EXAMPLE II
Preparation of 6-cyano-3,3-dimethyl-5-keto-6-(2-methylphenyl)hexanoic acid (METHOD II)
To a solution of sodium ethoxide in xylenes, prepared by adding 25 ml ethanol to 4.6 g of sodium metal suspended in 100 ml xylenes, refluxing 1 hr. then distilling out the excess ethanol, was added a solution of 13.1 g 2-methylphenylacetonitrile and 14.2 g 3,3-dimethylglutaric anhydride dissolved in 25 ml hot xylenes. The resulting slurry was held at reflux for 20 hrs with continuous removal of the by-product ethanol by distillation. The mixture was then cooled to ambient temperature and 100 ml cold water added. After stirring for 5 minutes the layers were separated and the organic layer extracted with an additional 50 ml of water. The combined aqueous layers were acidified to pH 2 with concentrated sulfuric acid and extracted twice with 75 ml ethyl ether. The combined ether extracts were dried over magnesium sulfate and the solvent removed under vacuum to produce a yellow gummy residue containing 17.75 g 6-cyano-3,3-dimethyl-5-keto-6-(2-methylphenyl)hexanoic acid. | This invention relates to the stoichiometric condensation of substituted phenylacetonitriles with dibasic carboxylic anhydrides. The resulting cyano-keto-acids are obtained in good yield and can be used to prepare biologically active 2-aryl-1,3-cyclohexanediones without elaborate purification. | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is related to pending U.S. provisional patent application No. 60/880,804, filed Sep. 20, 2013, and titled “PROTECTIVE COVER FOR A PORTABLE OR MOBILE DEVICE,” the entirely of which is incorporated herein by reference.
DESCRIPTION OF THE RELATED ART
[0002] The invention is directed to a cover device for a portable or mobile device, in particular for mobile phones and tablets, having a section configured to allow touch identification technology—such as fingerprint identification—already built into the portable device to work properly. An independent screen protector, or a case with screen protection, is provided that features a thinner zone/area to allow for touch identification (e.g., fingerprint scanning) on portable of mobile device (e.g., a phone or tablet device). This includes inserting a thin piece of film over just the button area, applying a thin film over the entire screen protector except over the screen area, and using forming tools to thin out the button area.
[0003] It is noted that citation or identification of any document in this application is not an admission that such document is available as prior art to the present invention.
[0004] Some portable devices now have touch identification technology built into the device so that a user can log into, or turn on, the device without having to enter a password or passcode. For example, the iPhone 5s now has a feature built into it called Touch ID, which includes a fingerprint identity sensor. With the iPhone 5s, a user can simply put a finger on the Home button and click, and the iPhone 5s unlocks.
[0005] With portable devices—especially mobile phones such as the iPhone 5s—it is advantageous to provide full coverage of the front surface of the device. Current cases with screen protection and individually sold screen protectors either feature a die cut hole around buttons (such as the Home button on an iPhone device) or they feature a formed piece of film or rubber overmold to cover the buttons. But in portable devices with touch identification technology, current films either prevent the touch identification sensors from operating properly—including films for iPhones and the like—or simply omit coverage, and thus protection from areas where sensors may be located. As such, those films and rubber coverings do not allow for features such as fingerprint scanners (such as Apple's Touch ID) to work with the devices. In the case of the iPhone 5s, when current films are placed over the fingerprint sensor prevent, the sensor is prevented from accurately reading your fingerprint.
[0006] It is noted that in this disclosure and particularly in the claims and/or paragraphs, terms such as “comprises”, “comprised”, “comprising” and the like can have the meaning attributed to it in U.S. Patent law; e.g., they can mean “includes”, “included”, “including”, and the like; and that terms such as “consisting essentially of” and “consists essentially of” have the meaning ascribed to them in U.S. Patent law, e.g., they allow for elements not explicitly recited, but exclude elements that are found in the prior art or that affect a basic or novel characteristic of the invention.
SUMMARY
[0007] It is an object of the current invention to provide full film coverage for the front of a portable device, while still allowing any touch identification technology (e.g., a fingerprint sensor) to operate and function properly. This object has been achieved by ensuring that the portion of the protective film which covers the touch identification sensor is thin enough to allow the sensor to properly register a user's touch so that the portable device can be operated.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIGS. 1A to 1E show one embodiment of the protective film for a portable device;
[0009] FIGS. 2A and 2B show another embodiment of the protective film for a portable device; and
[0010] FIG. 2C shows close-up and cutaway views of the embodiment shown in FIGS. 2A and 2B ;
[0011] FIGS. 3A and 3B show yet another embodiment of the protective film for a portable device; and
[0012] FIG. 3C shows another embodiment of the protective film for a portable device.
DETAILED DESCRIPTION OF EMBODIMENTS
[0013] It is to be understood that the figures and descriptions of the present invention have been simplified to illustrate elements that are relevant for a clear understanding of the present invention, while eliminating, for purposes of clarity, many other elements which are conventional in this art. Those of ordinary skill in the art will recognize that other elements are desirable for implementing the present invention. However, because such elements are well known in the art, and because they do not facilitate a better understanding of the present invention, a discussion of such elements is not provided herein.
[0014] The present invention will now be described in detail on the basis of exemplary embodiments.
[0015] FIGS. 1A to 1E show an embodiment where a portion of a first film 10 configured to cover a portable device 20 has been cut away in a location to form an opening 12 corresponding to a touch identification sensor of the portable device. A second, thinner film 11 is then attached to the first film 10 , so that the second film 11 is located in the area 12 corresponding to the touch identification sensor of the portable device. This attachment, for example to the underside of the first film 10 , can be achieved by using an adhesive 14 —such as an acrylic adhesive (e.g., VHB™), or any other suitable adhesive 14 —between the two films. Both the thicker first film 10 and thinner second film 11 would be formed around the sensor (e.g., the Home button on an iPhone device) so that the thinner second film 11 would sit flush with the sensor 22 .
[0016] Films with a thickness of 0.3 mm and greater are too thick to allow touch identification sensors to operate. Even films as thin as 0.15 mm, and some as thin as 0.12 mm, still prevent touch identification sensors from working. As such, the second film is configured with a thickness of less than 0.15 mm. Preferably the thickness of the second film is at least 0.04 mm and less than 0.12 mm. More preferably, the second film has a maximum thickness of 0.10 mm.
[0017] The second film can be made of any suitable transparent or sufficiently translucent film. Examples include clear plastics, such as polyethylene terephthalate (“PET”), polycarbonate (“PC”), polypropylene (“PP”), and acetate film.
[0018] PET films having thicknesses of 0.04 mm, 0.08 mm, and 0.10 mm were tested on the fingerprint identity sensor of the iPhone 5s, and all three films allowed the sensor to operate properly while still providing adequate protection for the area of the fingerprint identity sensor.
[0019] FIGS. 2A to 2C show an embodiment where a film 15 configured to cover a portable device is first formed with a thickness greater than 0.15 mm—in this case 0.3 mm. Then the protective film is compressed in an area 16 corresponding a touch identification sensor of the portable device, so that the compressed area 16 of the film has a thickness of less than 0.15 mm—in this case 0.10 mm or less. Zonal compression can be carried out by using methods such as, for example, employing a forming tool having male 17 and female compression 18 elements configured to compress the film in an area 16 corresponding a touch identification sensor of the portable device such that, for example, the compressed area 16 is flush with the sensor. This zonal compression provides a single-film cover for the portable device, as compared to the dual-film form of the embodiment shown in FIGS. 1A and 1B . As such, no adhesive is needed. The benefits of both embodiments are readily apparent to one of ordinary skill in the art.
[0020] FIGS. 3A and 3B show another two-piece design for a protective film. In this embodiment, a first film which covers most of the portable device is formed. As in FIGS. 1A and 1B , at least a portion 12 of the first film 10 corresponding to the touch identification sensor has been cut away. A second film 11 is then formed to cover the front of the portable device except for the screen area. This second film 11 is formed so that at least the portion of second film 11 corresponding to the touch identification sensor has a thickness of less than 0.15 mm—in this case 0.10 mm or less. This can be achieved by forming the second film 11 to have a single thickness of less than 0.15 mm, or by forming the second film to have multiple thicknesses using any of the procedures discussed above with respect to FIGS. 1A-2B . The second film 11 can then be attached to either the front or the back of the first film—with FIGS. 3A and 3B showing the second film layered on top of the first film and FIG. 3C showing the second film 11 layered underneath the first film 10 .
[0021] In addition, the portions 9 of the second film 11 which do not correspond to the touch identification sensor of the mobile device can be configured to be tinted or colored. For example these non-sensor areas can have a printed design or pattern—so long as a portion 13 of the second film 11 which corresponds to the sensor is clear, or sufficiently translucent to allow the touch identification sensor to function properly.
[0022] The above embodiments can be used to create individual screen protector devices, or can be incorporated into mobile device cases—including waterproof cases. In terms of an individual screen protector, the above embodiments provide both screen and button/sensor protection, while also allowing any sensors—including those incorporated into buttons—to sense fingerprints. In terms of a case with screen protection, it allows the case to be waterproof and to seal off front screen side buttons while allowing activation of a button's integrated touch identification sensor.
[0023] While this invention has been described in conjunction with the specific embodiments outlined above, it is evident that many alternatives, modifications, and variations will be apparent to those skilled in the art. Accordingly, the preferred embodiments of the invention as set forth above are intended to be illustrative, not limiting. Various changes may be made without departing from the spirit and scope of the inventions as defined in the following claims. | A cover device for a portable or mobile device, in particular for mobile phones, having a section configured to allow touch identification technology—such as fingerprint identification—already built into the portable device to work properly. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to systems for the filling, transport, and emptying of liquid containers More particularly, the invention concerns a novel, corrosion resistant liquid extraction apparatus that includes a novel plastic valve that can be removably connected to a liquid transport container. In turn, the valve can be interconnected with a specially configured, corrosion-resistant, plastic coupler that operates the valve in a manner to enable fluid to be extracted from the container.
2. Discussion of the Prior Art
The storage and transport of liquids and particularly the storage and transport of hazardous liquids have long presented substantial problems. For many years liquids were stored and transported in throwaway type metal and plastic containers. Typically, such containers were provided with a threaded liquid outlet port, which, after the container was filled, was closed, by some type of threaded cap. The use of these types of containers was costly, inefficient and often hazardous, particularly when the containers were used to store and transport potentially dangerous chemicals.
In recent years substantial efforts have been made to develop new systems to improve container and drum management capabilities, minimize user exposure to hazardous materials and address emerging governmental regulations. These efforts have resulted in the development of several different types of reusable systems for transferring liquid formulations from returnable closed drums and containers. As a general rule, these systems to a greater, or lesser extent, simplify drum emptying, minimize operator hazards, improve cleanliness and eliminate costly waste inherent in prior art disposable container systems. One of the most advanced of such improved systems was developed by and is presently commercially available from Micro Matic, Inc. of Northridge, Calif.
The Micro Matic system, which is described in U.S. Pat. No. 5,901,747 issued to the present inventor, basically comprises a two-part system that includes a coupler operated extractor valve which can be interconnected with a conventional drum via existing threaded connections and a cooperating coupler which connects to the extractor valve to allow drum emptying through the use of a remote pumping system. The extractor valve apparatus includes a valve body and a down tube connected to the valve body, which extends to the bottom of the drum to permit the complete transfer of liquid from the drum.
Another Micro Matic prior art liquid transfer system is described in U.S. Pat. No. 5,944,229 also issued to the present inventor. This invention concerns a novel, tamper-proof, safety valve system that includes a tamper evident valve closure cap that must be broken before liquid can be removed from the container.
The Micro Matic systems, while representing the best of the current state of the art liquid transfer systems, have certain drawbacks which are sought to be overcome by the system of the present invention More particularly, the metal valve and coupler assemblies of the Micro Matic systems are of a relatively complex design making them somewhat difficult and costly fabricate. Further, in some respects these metal assemblies are not well suited for use with various types of hazardous and highly corrosive chemicals that are frequently stored and transported.
As will be better appreciated from the discussion that follows, unlike the prior art Micro Matic systems, the novel valve and coupler of the improved system of the present invention are of an elegantly simple design and are uniquely constructed from a corrosive resistant plastic that is substantially impervious to most corrosive liquids. Additionally, the improved system provides a customer unique, key type coupler-valve mating interface that precludes removal of the drum contents by unauthorized persons
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a novel liquid transfer system that includes a valve and coupler assembly of unique design for use in extracting hazardous fluids from a transport container. More particularly, it is an object of the invention to provide a liquid transfer system of the aforementioned character that includes a novel valve and coupler assembly that is of a simple design and is uniquely constructed from a corrosive resistant plastic that is substantially impervious to most corrosive liquids.
Another object of the invention is to provide a system of the character described which improves container and drum management while at the same time significantly reducing the material and labor costs inherent in the fabrication of the prior art liquid transfer systems.
Another object of the invention is to provide a liquid transfer system, which includes a novel plastic valve mechanism, which can be readily removably connected to a container such as a metal or plastic drum, and a novel, plastic coupler mechanism that can be removably coupled with the plastic valve mechanism for operating the valve mechanism. An important aspect of the liquid transfer system resides in the fact that the valve mechanism is specially configured so that only a coupler of a special, mating configuration can be interconnected with the valve mechanism. In this way, couplers and valves can be custom designed for individual users and use of or tampering with containers belonging to the individual user by users of similar systems is positively prevented.
Another object of the invention is to provide a fluid transfer system of the aforementioned character, which is highly reliable in operation, has a long useful life and is easy to use with a minimum amount of instruction being required.
Another object of the invention is to provide a system of the character described in the preceding paragraphs, which is inexpensive to produce and requires minimum maintenance.
In summary, the novel liquid transfer system of the present invention includes a valve and coupler assembly of unique design and a remote pump means that can be connected to the coupler to extract hazardous fluids from a transport container. The plastic valve of the system comprises a valve body that is connected to the container, which includes a coupler receiving portion and a hollow skirt portion, the hollow skirt portion having a spiral groove formed therein. An insert having a central bore is sealably received within the skirt portion for rotational movement by the coupler between a first valve closed position and a second valve open position. A down tube assembly is connected to the valve body and includes a stem portion that is sealably received within the central bore of the insert. The coupler of the liquid transfer system, which includes a fluid outlet passageway in communication with the fluid passageway of the down tube assembly, can be conveniently, removably connected to the valve body for imparting rotation to the insert. The plastic valve further includes a radially outwardly extending protuberance that is closely receivable within said spiral groove of the skirt portion of said valve body and the coupler receiving portion of the valve body is provided with circumferentially spaced openings which receive circumferentially spaced blades provided on the coupler. The insert of the plastic valve, in turn, includes upstanding fingers that are engagable by the spaced-apart blades when the coupler is connected to said valve body. In one form of the invention, the coupler also includes a downwardly extending first sleeve, an upwardly extending second sleeve telescopically received within the first sleeve and biasing means for yieldably resisting telescopic movement of the second sleeve into the first sleeve.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a generally perspective, exploded view of one form of the liquid transfer system of the invention showing the fluid container broker away to reveal internal construction.
FIG. 2 is a generally perspective exploded view of one form of the coupler assembly and valve assembly of the invention.
FIG. 3 is a greatly enlarged fragmentary top plan view of a portion of the system shown in FIG. 1 .
FIG. 4 is a view taken along lines 4 — 4 of FIG. 3, partly broken away to show internal construction.
FIG. 5 is a cross-sectional view taken along lines 5 — 5 of FIG. 4 .
FIG. 6 is a cross-sectional view taken along lines 6 — 6 of FIG. 4 .
FIG. 7 is a planer projection of the upper portion of the valve assembly of the invention and the lower portion of the coupler assembly showing the manner in which the coupler blades interact with the valve assembly.
FIG. 8 is a view similar to FIG. 3 but showing the coupler moved into a valve open position.
FIG. 9 is a cross-sectional view similar to FIG. 4, but showing the valve assembly in a valve open configuration.
FIG. 10 is a cross-sectional view taken along lines 10 — 10 of FIG. 9 .
FIG. 11 is a cross-sectional view taken along lines 11 — 11 of FIG. 9 .
FIG. 12 is a planer projection similar to FIG. 7, but showing the valve assembly having been moved into a valve open configuration.
FIG. 13 is a generally perspective, exploded view of an alternate form of the valve and coupler assembly of the invention.
FIG. 14 is a top plan view of the assembly shown in FIG. 13, partly broken away to show internal construction.
FIG. 15 is a generally perspective, exploded view of yet another embodiment of the invention.
FIG. 16 is a top plan view of the embodiment shown in FIG. 15 partly broken away to show internal construction.
FIG. 17 is a generally perspective view of still another form of the coupler and valve assembly of the invention.
FIG. 18 is a top plan view of the assemblage shown in FIG. 17 partly broken away to shown internal construction.
DESCRIPTION OF THE INVENTION
Referring to the drawings and particularly to FIG. 1, one form of the apparatus is there shown interconnected with a conventional liquid transport container “C”. Container “C” includes interconnected top, bottom and side walls “T”, “B”, and “S” respectively that define a liquid reservoir “R”. The apparatus of the invention here comprises a valve assembly 20 that is threadably connected with top wall “T” of the container, a coupler assembly 22 that can be removably interconnected with valve assembly 20 and a remotely located pumping means “P” for pumping the liquid “L” from the transport container. As best seen in FIG. 2, valve assembly 20 comprises a valve body 24 that is threadably connected to top wall “T” of container “C” by conventional threads 26 formed on the valve body. Valve body 24 includes a tubular shaped skirt portion 28 that is provided with a plurality of circumferentially spaced, curved grooves 30 , the purpose of which will presently be described. The top wall 24 a of valve body 24 is provided with a plurality of circumferentially spaced irregularly shaped openings 32 which here are generally fan shaped.
Valve assembly 20 farther includes a generally cylindrically shaped insert 36 that is rotatably received within skirt portion 28 of valve body 24 . In a manner presently to be described, insert 36 can be moved by the coupler assembly 22 from a first valve closed position to a second valve open position. As best seen in FIG. 6, insert 36 is provided with a central, generally cylindrically shaped bore 38 that telescopically receives upper portion 42 a of stem 42 which forms a part of a down tube assembly generally designated by the numeral 44 (FIG. 2 ). Down tube assembly 44 also includes a flange portion 45 that is interconnected with skirt 28 of valve body 24 in the manner shown in FIG. 6 . As indicated in FIG. 6, stem 42 is connected to and extends both upwardly and downwardly from flange 46 . The upper portion 42 a of the stem, which carries an elastomeric O-ring 43 , is sealably received within central bore 38 of insert assembly 36 , while the lower portion 42 b extends downwardly within reservoir “R”. As indicated in FIG. 2, the upper portion 42 a of stem 42 is provided with a plurality of circumferentially spaced fluid passageways 46 . As will presently be described, when the coupler assembly 22 is interconnected with the valve assembly and is rotated into the valve-open position, fluid passageways 46 will move into communication with an outlet passageway formed in coupler assembly 22 , which, in turn, communicates with the pumping means “P” (FIG. 1 ).
Turning particularly to FIGS. 2 and 6, the novel coupler assembly of the present invention can be seen to comprise an upper gripping portion 22 a having finger gripping segments 22 b and a lower, downwardly extending, generally tubular portion 22 b . Affixed to portion 22 b of the coupler assembly are circumferentially spaced blade-like members 50 which engage circumferentially spaced surfaces 52 formed on a plurality of upstanding, finger-like portions 54 that comprise a part of insert 36 .
As indicated in FIG. 4, when the coupler assembly 22 is mated with the valve assembly, the generally fan shaped blades 50 will be received within the fan shaped openings 32 and the edges thereof will engage walls 52 of fingers 54 upon rotation of the coupler. With this construction, rotation of coupler assembly 22 relative to valve assembly 24 will cause blades 50 to impart rotation to insert 24 between the first valve closed position shown in FIG. 6 and the second valve open position shown in FIG. 11 . In this regard, it is to be noted that protuberances 40 of insert 36 are received within curved grooves or slots 30 so that, upon rotation of insert 36 by the coupler assembly 22 , protuberances 40 will move along grooves 30 urging downward movement of insert 36 from the valve closed position shown in FIG. 6 to the valve open position shown in FIG. 11 (see also FIGS. 7 and 12 ).
As indicated in FIG. 6, when the valve is in the closed position, a valve seat-engaging sleeve 56 formed on coupler assembly 22 will sealably engage a valve seat 58 formed on upper stem portion 42 a . When the valve is in the valve open position illustrated in FIG. 11, it is to be noted that outlet passageways 46 provided in stem portion 42 a can freely communicate with outlet passageway 60 formed in coupler assembly 22 and with the pumping means (FIG. 1 ). Accordingly, when the valve is in the valve open position shown in FIG. 11, upon urging of the pumping means, the liquid “L” can be drawn from the container “C” upwardly through the down tube assembly in the direction of the arrow 61 in FIG. 11, through outlet passageways 46 , into passageway 60 and then outwardly of the apparatus in a direction toward the pump means “P”. Pump means “P” can comprise any suitable commercially available pump of a character well understood by those skilled in the art.
As illustrated in FIGS. 6 and 11, coupler assembly 22 includes a downwardly extending sleeve 64 which telescopically receives an upwardly extending sleeve 66 . Sleeve 66 terminates in an end wall 66 a that engages the top of valve seat 58 . Disposed within sleeves 64 and 66 is biasing means for yieldably resisting telescopic movement of second sleeve 66 into first sleeve 64 . This biasing means is here provided in the form of a conventional coil spring 68 . As indicated in FIG. 11, as the coupler assembly is rotated into the valve open position there shown, spring 68 will be compressed in a manner that will urge coupler 22 to return to its upward, valve closed position as shown in FIG. 6 .
With the construction described in the preceding paragraphs, as the coupler assembly is rotated relative to the valve assembly, from the position shown in FIGS. 3 and 4 to the position shown in FIGS. 8 and 9, valve seat engaging sleeve 56 will move telescopically downwardly over the upper portion 42 a of stem 42 against the urging of the biasing means or spring 68 . When the coupler assembly reaches the position shown in FIG. 11, valve seat engaging sleeve 56 will have moved telescopically downwardly relative to stem portion 42 a to a position where outlet passageways 46 are in fluid communication with passageway 60 formed in coupler assembly 22 . With the apparatus in the valve-open position, energization of pump “P” will, of course, cause fluid to be drawn from the container “C” outwardly of the apparatus in the direction toward pump “P”. Rotation of coupler assembly 22 in the opposite direction will, of course, cause the apparatus to return to the valve closed position shown in FIG. 6 where sleeve 56 will sealably engage valve seat 58 .
Turning to FIGS. 13 and 14, an alternate form of the apparatus of the invention is there shown. This form of the invention is similar in most respects to that shown in FIGS. 1 through 12 and like numerals are used to identify like components. However, in the embodiment of the invention shown in FIGS. 13 and 14, the circumferentially spaced openings 71 formed in the valve body are of a slightly different configuration as are the blades 73 of the coupler assembly. More particularly, as indicated in FIG. 13, blades 73 are provided with a plurality of key-like shoulders 73 a that are closely received within the keyhole-like openings 71 provided in the valve assembly. It is apparent that, unless the coupler is provided with the correctly configured blades, the coupler cannot be used in conjunction with the valve body 24 of the character shown in FIG. 13 .
Turning to FIGS. 15 and 16, still another form of the apparatus of the invention is there shown. Once again, this apparatus is similar to that previously described and like numerals are used to identify like components. In the embodiment of the invention shown in FIGS. 15 and 16, the circumferentially spaced openings 75 formed in the valve assembly are of a different configuration from that shown in FIGS. 1 through 12, but are similar to those shown in FIGS. 13 and 14. Similarly, the blades 77 formed on the coupler assembly are of a different configuration from those shown in FIGS. 1 through 12. However, the blades in the apparatus shown in FIGS. 15 and 16 are of similar configuration to those shown in FIGS. 13 and 14. Although this is the case, as indicated by the arrow 79 in FIG. 15, in this latest embodiment of the invention, the coupler is rotated in a counterclockwise direction rather than a clockwise direction to move valve assembly from a valve closed position to a valve open position. Once again, with this important distinction, unless the coupler is provided with properly configured blades 77 , the coupler cannot be used with the valve assembly having the configuration shown in FIG. 15 .
Referring next to FIGS. 17 and 18, yet another form of the apparatus of the invention is there shown. Again, this form of the apparatus is similar in most respects to the apparatus previously described and like numerals are used in FIGS. 17 and 18 to identify like components. In this latest embodiment of the invention, it is to be noted that the operating blades 81 of the coupler assembly and the openings 83 provided in the valve assembly are once again of a different configuration. More particularly, as best seen in FIG. 17, blades 81 include a central radially outwardly extending protuberance 81 a that is received within a notch-like opening 83 a that forms a part of each of the blade receiving openings of the valve assembly.
It is clear from a study of FIGS. 13 through 18 that the coupler assemblies as well as the valve assemblies can be specially configured for particular customer so that only couplers belonging to that customer can be used to operate valves belonging to the customer.
It is to be understood that the configuration of the blades and openings of the apparatus shown in the drawings is only exemplary, and that any number of mating configurations of blades and openings can be provided to the customer.
Having now described the invention in detail in accordance with the requirements of the patent statutes, those skilled in this art will have no difficulty in making changes and modifications in the individual parts or their relative assembly in order to meet specific requirements or conditions. Such changes and modifications may be made without departing from the scope and spirit of the invention, as set forth in the following claims. | A liquid transfer system that includes a valve and coupler assembly of unique design for use in extracting hazardous fluids from a transport container. The system includes a novel valve and coupler assembly that is of a simple design and is uniquely constructed from a corrosive resistant plastic that is substantially impervious to most corrosive liquids. | 1 |
FIELD OF THE INVENTION
The present invention relates in general to garage door systems, and is particularly directed to a door bracing system made of grooved telescoping column members, that are attachable to a garage door and to the structure of the garage building proper, so as to reinforce and anchor a multi-paneled garage door against high velocity winds and against intrusive using instruments.
BACKGROUND OF THE INVENTION
A typical multi-panel residential garage door is comprised of a plurality of panels (usually made of galvanized steel or fiberglass), which are hinged together at hinge joints. The hinge joints are equipped with side wheels or rollers that ride in a pair of guide tracks that extend along opposite sides of the garage door opening. The guide tracks are usually anchored (e.g., bolted) to wall regions of the garage adjacent to the opening and attached via brackets to the ceiling. The door may be opened and closed either by hand or by way of an automated garage door translation device, such as may be mounted to the ceiling and attached to the topmost one of the door panels.
As described in DeCola et al, U.S. Pat. No. 5,620,038, entitled: “System for Bracing Garage Door Against Hurricane Force Winds”, also described in Decola, U.S. Pat. No. 5,964,269, entitled: “System of Telescoping Longitudinally Grooved Door-Stiffening Columns For Bracing Garage Door Against Hurricane Force Winds”, and as described in Decola, U.S. Pat. No. 6,082,431, entitled: “System of Telescoping Longitudinally Grooved Door-Stiffening Columns For Bracing Garage Door Against Hurricane Force Winds,” (the disclosure of each of which is incorporated herein by reference in its entirety), when a multi-panel garage door is exposed to high velocity winds of a violent storm, such as a hurricane, the door panels have a tendency to separate from the guide tracks as a result of continued flexing of the panels and fatigue of the tracks themselves. This repeated flexing causes the side wheels to become detached from the tracks so that the ends of panels become warped, allowing wind to enter the garage and literally rip or ‘peel’ the door away from the garage door opening. Once the garage and adjacent structure has been blown out, the ceiling of the garage and adjacent structure are no longer protected from the extremely high velocity winds of the storm, and it is simply a matter of time before the roof blows off, causing the entire structure to be destroyed.
Follow-up investigation to the widespread damage to residential buildings in south Florida by Hurricane Andrew in 1992 has revealed that had garage doors been reinforced against such separation from the guide tracks, and not blown out, the full force of the hurricane would not have been able to enter many of the destroyed houses. As a result of this investigation, homebuilders in coastal areas of south Florida are required to provide some form of hurricane reinforcement for their garage doors. Recommendations of how to accomplish this have usually involved the installation of (metal or wooden) girts that extend horizontally across each panel. Such girts are intended to stiffen the panels and prevent their oscillatory motion that leads to the destructive separation from the tracks.
Unfortunately, such stiffening panels add considerable weight to the door, requiring adjustments of both the lifting coil spring and of the drive of the automated garage door translation mechanism. Moreover, even with such adjustment, the substantial weight of the girts, for which neither the door nor the automated translation mechanisms were originally designed, leads to further wear and tear of the automatic garage door opener. Yet, even with such stiffeners, the fundamental problem they are intended to solve is not remedied, since they do not prevent torquing of the panels at the point of attachment of the door to the tracks, and do not effectively relieve the wind load placed on the entire garage door opening. The girts are unable to prevent torquing since they extend horizontally-making them parallel to joint lines between panels. Such an orientation provides axes of rotation, about which the panels are torqued when subjected to high velocity winds. The girts provide neither reinforcement nor a separation barrier along the lengths of the tracks, nor do they make the door a wind-loadable door.
Advantageously, the door-bracing system described in the above-reference patents remedies these shortcomings, by means of a door bracing system that contains a plurality of door-stiffening column members that are installed between associated upper mounting brackets above the garage opening and lower mounting brackets affixed to the garage floor. The door bracing system also includes deflection brackets which attach the door panel hinge joints to the column members, so that the entire vertical extent of the garage door is effectively braced against high velocity winds, and thereby prevented from separating along the guide tracks.
Problems Of The Prior Art
Although the inventions described in U.S. Pat. Nos. 5,620,038; 5,964,269 and 6,082,431 represented a significant advancement over the prior art, each of those patents required that the vertical supports mount to the building housing the garage door above the top of the garage door opening. This made it less convenient to use with a roll type garage door without extraordinary efforts. Further, each of those patents require the replacement of hinge pins with longer ones used to connect the panels of the garage door to the vertical supports. Further, there is a lack of flexibility of location in positioning the vertical supports. Further, the top connection of the vertical supports were bolted to the building, which made them difficult to remove once the threat of a hurricane passed. Thus, installation and removal is more difficult.
Further, when a vertical support was placed in between the tracks for the garage door, there was not a positive connection which would protect against both positive and negative air pressure surges.
Finally, the prior art did not allow easy assembly and shipping to a customer in a kit form for do-it-yourself installation.
BRIEF SUMMARY OF THE INVENTION
The invention is directed to apparatus and techniques for bracing garage doors against hurricane force winds which overcome the problems of the prior art. More specifically, the invention is directed to:
Apparatus for bracing roll down doors of a building having a plurality of substantially horizontal door panels, against severe winds, comprising:
a. a horizontal cross bar mounted to the building at connector locations on either side of the door panels; b. at least one vertical support bar connected to the horizontal cross bar at a location intermediate to the ends of the horizontal cross bar and secured to the floor using a floor mount; c. at least one attachment mechanism for connecting the vertical support bar to a panel of the roll down door.
The attachment mechanism comprises a rotatable hook.
The attachment mechanism comprises a bracket having a channel for receiving the rotatable hook mounted to a door panel.
The bracket comprises front and back pieces secured to the door panel through openings in the door panel.
The vertical support bar is connected to the horizontal cross bar using a bracket which substantially surrounds the vertical support bar and surrounds the sides and top portion of the horizontal cross bar.
The vertical support bar comprises telescoping sections, each having a rectangular cross section with T channels extending the length of the vertical support bar.
Bolts are used to secure a channel slide piece to the vertical support bar with the heads of the bolts inserted into a T channel and in which nuts are screwed onto the bolts and tightened to secure the channel slide piece to the vertical support bar at a selected location.
Another bolt extends through a portion of the channel slide piece to secure a rotatable hook to the channel slide piece.
The horizontal cross bar is mounted to the building at a connector location using at least one L bracket of common design.
A single L bracket may be bolted to a wood, concrete or steel plate on one face and secures the horizontal cross bar to the other face using a U shaped connector.
Two L brackets may be bolted to a wood, concrete or steel plate on opposite sides of the plate and both L brackets secure the horizontal cross bar to the other faces using a U shaped connector passing through both brackets.
The horizontal cross bar is placed between the other faces of the L brackets and is held in place using a U shaped connector passing through both brackets.
Two L brackets may be bolted to a wood, concrete or steel plate on the same side of the plate and in which the horizontal cross bar is placed between the other faces of the said L brackets and is held in place using a U shaped connector passing through both brackets.
One face of a first L bracket may be mounted to a first vertical surface with the other face lying on a horizontal surface, and a second L bracket may be mounted to a second vertical surface below the horizontal surface with the second face of the second bracket being parallel the other face of the first bracket.
The horizontal cross bar may be mounted between the other face of the first L bracket and the second face of the second L bracket.
Two L brackets may be used, in which the first L bracket is bolted to a wood, concrete or steel plate on one face and secures the horizontal cross bar to the other face using a U shaped connector, and a second L bracket is connected to a mounting support for a roll of panels for the garage door horizontally displaced from the first L bracket and in which one end of the first L bracket is attached to the second L bracket using a small bracket.
The invention is also directed to a method for bracing roll down doors of a building having a plurality of substantially horizontal door panels against severe winds, comprising:
a. mounting a horizontal cross bar to the building at connector locations on either side of the door panels; b. providing at least one vertical support bar connected to the horizontal cross bar at a location intermediate to the ends of the horizontal cross bar and secured to the floor using a floor mount; c. connecting the vertical support bar to at least one panel of the roll down door using an attachment mechanism.
The attachment mechanism in the method comprises a bracket having a channel mounted to a door panel for receiving a rotatable hook.
The invention is also directed to a kit for bracing roll down doors of a building having a plurality of substantially horizontal door panels against severe winds, comprising:
a. a plurality of L brackets; b. one horizontal cross bar; c. at least one vertical support bar; d. a floor mounting bracket; and e. at least one bracket for substantially surrounding a vertical support bar and for engaging said horizontal cross bar.
The at least one vertical support bar in the kit may be a telescoping vertical support bar.
The at least on vertical support bar of the kit has a substantially rectangular cross section with at least one T channel extending the length of the vertical support bar.
The kit further comprises at least one bracket for attaching to a door panel and a rotatable hook for rotating into engagement with the bracket and connecting to the vertical support bar.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1A , 1 B, and 1 C are perspective views of a single, double and triple vertical support for respective, single, double and triple wide garage doors in accordance with one aspect of the invention.
FIG. 2 shows a perspective view of hardware used to attach a telescoping vertical support to the garage door in accordance with one aspect of the invention.
FIG. 3 illustrates a backside piece for attachment to a garage door panel.
FIG. 4 illustrates a front side piece having a U shaped channel for attachment to a garage door panel.
FIG. 5 illustrates a hook piece that rotates to fit into the U shaped channel of FIG. 4 to connect the door to the telescoping vertical support.
FIG. 6 illustrates a channel slide piece that can be adjusted vertically in a T channel track of a vertical support.
FIG. 7 illustrates an alternative technique for connecting the garage door to the vertical support.
FIG. 8 illustrates a first technique for mounting the horizontal cross bar shown in FIG. 1 to the building.
FIG. 9 shows details of the L bracket illustrated in FIG. 8 .
FIG. 10 shows a second technique for mounting the horizontal cross bar to the building.
FIG. 11 shows a third technique for mounting the horizontal cross bar to the building.
FIG. 12 shows a fourth technique for mounting the horizontal cross bar to the building.
FIG. 13 shows a fifth technique for mounting the horizontal cross bar to the building.
FIG. 14 shows a sixth technique for mounting the horizontal cross bar to the building.
FIG. 15 shows a seventh technique for mounting the horizontal cross bar to the building.
FIG. 16 is a perspective view of a small bracket used in the mounting arrangement of FIG. 15 .
FIG. 17 is a perspective view of an assembly showing how to connect a vertical support to the horizontal cross bar shown in FIGS. 1A , 1 B and 1 C in accordance with one aspect of the invention.
FIG. 18 is a perspective view of the bracket used in FIG. 17 .
FIG. 19 is a detailed view of a preferred version of the bracket shown in FIG. 18 .
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1A shows a perspective view of a single vertical support for a singlewide garage door in accordance with one aspect of the invention. The telescoping vertical support 100 is mounted to the floor using a mounting bracket 115 in ways that are shown in the prior art. When the vertical support is removed, the mounting bracket 115 can be removed for normal operation during a time when no hurricane is threatened. The vertical support 100 connects to a cross bar 110 using a bracket 120 , described more hereinafter. The vertical support is connected to at least one panel of the garage door using bracket 130 , as described more hereinafter. The horizontal cross bar 110 is mounted to the wall of the building using one or more brackets as described more hereinafter.
FIGS. 1B and 1C show perspective views of a double and triple vertical support for double and triple wide garage doors in accordance with one aspect of the invention. In each of these figures, the vertical support 100 is replicated two or three times to accommodate the size of the garage doors.
FIG. 2 shows a perspective view of hardware used to attach a telescoping vertical support to the garage door in accordance with one aspect of the invention. Depiction of the thickness of the garage door is not illustrated to permit a view of the mounting of the brackets to the garage door to be visualized more readily. The mounting to the garage door occurs using a rear bracket 200 and a front bracket 210 . The two brackets are positioned on opposite sides of a panel thickness for the garage door and are sized so as to permit the panel of the garage door to roll up and be stored in its usual fashion. Bracket 210 has a U channel, described more hereinafter. A channel slide 220 fits into the T channel on the vertical support and can be moved into position and then secured by tightening the nuts associated with the bolt, the bolt head of which rides in the channel. A third bolt, extending from the channel slide is utilized to mount a hook 230 , the point of which fits into the U channel of the front bracket 210 of the door mounting brackets.
FIG. 3 illustrates a rear bracket piece 200 of a door-mounting bracket for attachment to the garage door panel. The material for the bracket is ⅛ GA steel.
FIG. 4 illustrates the front bracket 200 having a U shaped channel 212 for attachment to the garage door.
FIG. 5 illustrates a hook piece 230 that rotates to fit into the U shaped channel 212 of FIG. 4 to connect the door mounting brackets to the telescoping vertical support 100 .
FIG. 6 illustrates the details of the construction of a channel slide piece 220 that can be adjusted vertically in a track of a vertical support 100 .
FIG. 7 illustrates an alternative technique for connecting the garage door to the vertical support. In this case, a bracket 700 is mounted to the vertical slide using the bolt heads to guide the bracket positioning of the bracket in the T channel of the vertical support. The bracket 700 is configured to receive and mount a spring-loaded J channel 702 which can be inserted into the holes of the front side door mounting brackets 211 of slightly modified construction shown in FIG. 7 . To remove the J channel 702 , the channel is pulled to the left until it clears the holes and then it can be released to be held in place by the spring 214 for use when it is installed at a later time. The spring 214 keeps the J channel 702 out of the way when the vertical supports are stored when no hurricane threat is present.
FIG. 8 illustrates a first technique for mounting the horizontal cross bar 110 shown in FIG. 1A to the building. As shown, the horizontal cross bar is held in place by a U channel 300 inserted through the lower portion of an L bracket 302 , the vertical portion of which is mounted to a wood, concrete or steel plate securely fastened to the building. The details of the L bracket 302 illustrated with FIG. 8 are shown in FIG. 9 .
FIG. 10 shows a second technique for mounting the horizontal cross bar 110 to the building. This technique uses two L brackets 302 , one on either side of a plate to provide additional strength.
FIG. 11 shows a third technique for mounting the horizontal cross bar 110 to the building. This technique also utilizes two L brackets 302 with the bottom piece of each L bracket being on opposite sides of the channel cross bar.
FIG. 12 shows a forth technique for mounting the horizontal cross bar 110 to the building. This figure is like FIG. 11 , except that both L brackets 302 are mounted on the same side of the mounting plate.
FIG. 13 shows a fifth technique for mounting the horizontal cross bar 110 to the building. In this case, one L bracket 302 is utilized to mount to a plate against one portion of the building and a second L bracket 305 , mounted below, accommodates the step nature of the building construction at the point of attachment.
FIG. 14 shows a sixth technique for mounting the horizontal cross bar 110 to the building. Again, there is a step displacement which can be utilized effectively by mounting two L brackets 302 and 305 , one above and one below the cross bar position.
FIG. 15 shows a seventh technique for mounting the horizontal cross bar 110 to the building. In this case, this technique is similar to that shown in FIG. 8 except that a small bracket 1500 is utilized to displace an L bracket 305 so that it can attach underneath the bracing to which the roll for the garage door panels is mounted. This allows yet added strength.
FIG. 16 is a perspective view of a small bracket 1500 used in the mounting arrangement of FIG. 15 . Each of the techniques for mounting the horizontal cross bar to the building shown in FIGS. 8-15 , utilize the same L bracket. That is, the construction of the L bracket is such as to accommodate a variety of configurations and mountings. This allows a single piece to have multiple uses and to reduce the number of pieces that might need to be stored or fabricated for an installation by homeowner in a do-it-yourself installation.
FIG. 17 is a perspective view of an assembly showing how to connect a vertical support to the horizontal crossbar shown in FIGS. 1A , 1 B and 1 C.
FIG. 18 provides a perspective view of the bracket 120 used in the attachment of FIG. 17 .
FIG. 19 provides a detailed view of a preferred version of the bracket 120 shown in FIG. 17 .
Returning to FIG. 17 , one can see that the bracket and the mounting bolt locations are configured so that the head of the mounting bolts can slide in the T channels of the vertical support, allowing it to be adjustable up and down the vertical support.
Turning again to FIG. 1A , the vertical cross bar (s) the horizontal cross bar, the L brackets for mounting, the door mounting brackets 130 can be conveniently packed and shipped as a kit for easy installation by a homeowner, authorized dealer or contractor. Once installed, the vertical supports can be easily removed by disconnecting the hook from each of the door panel mounting brackets and by sliding the vertical brace 100 on crossbar 110 to either side of the horizontal bar to be secured to the side wall or by lifting the bracket 120 attached to the vertical support 100 so that the top of the bracket 120 clears the horizontal cross bar so that it can be removed and stored. The floor bracket is fastened to the vertical brace and moves with the vertical brace. Push rods can be used to slide into 2 predrilled holes thru a plate fastened in the floor. This plate will remain in the floor and can be driven over etc. Thus, with the L brackets and the cross bar in place, a homeowner can quickly and easily slide the rods into the floor bracket into previously drilled holes, connect or slide the vertical support(s) to or on the horizontal cross bar using bracket 120 , adjust the channel slides to the corresponding heights of the U channels of the door mounting brackets and have a positive connection between the door panels and the vertical support bar that will protect the door against both positive and negative pressure. The sizing of the door mounting brackets are such that they can be accommodated in the roll up of the door panels when the door is open.
There has thus been described an extremely effective and easy to install method of protecting garage doors during a threat of a hurricane or used for security when installed to prevent the rollup door from opening. The installation as described can be done quickly, on short notice once a wind storm is threatened. Once the threat is past it can be removed and stored using a minimum of space.
The arrangement described provides easy installation even by a do-it-yourself homeowner. The arrangement described also allows itself to be shipped conveniently as a kit from a distribution point to the homeowner.
While various embodiments of the present invention have been illustrated herein in detail, it should be apparent that modifications and adaptations to those embodiments may occur to those skilled in the art without departing from the scope of the present invention as set forth in the following claims. | Equipment and techniques for bracing roll down doors of a building having a plurality of horizontal door panels against severe winds and security against burglary use a horizontal cross bar mounted to the building at connector locations on either side of the door panels. At least one vertical support bar connects to the horizontal cross bar at locations intermediate to the ends of the horizontal cross bar and is secured to the floor using a floor mount. The vertical support bar is connected to door panels using a rotatable hook. The equipment can be provided in a kit form for easy installation. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 13/087,653, filed Apr. 15, 2011, now U.S. Pat. No. 9,151,079, which claims the benefit of U.S. Patent Application No. 61/324,698, filed Apr. 15, 2010, which are hereby incorporated by reference in their entirety.
TECHNICAL FIELD
[0002] The present invention relates to electrically operated devices associated with a door or closure, more particularly, to mechanisms for electrically locking or unlocking a door in a frame; further, to such mechanisms wherein the power to operate the electrical mechanism is collected and provided by an energy harvester; and most particularly, to an electric door release mechanism which may be actuated by a piezoelectric actuator powered by an energy harvester such as, for example, a piezoelectric energy harvester.
BACKGROUND OF THE INVENTION
[0003] So-called “energy harvesters” and “energy harvesting” refer generally to apparatus and methods for collecting and storing energy present in the environment, such as heat or solar energy, RF energy, and kinetic energy such as low frequency excitation or rotation. Such energies are referred to herein as “waste” or “free” energies. Storing is typically in the form of conversion of waste energy to electricity for subsequent storage in a battery.
[0004] Electrically operated devices that are mounted in or on a door or at a remote closure, such as, for example, electric door release mechanisms, illumination devices video screen displays, keypads and signage, are known. Electric door release mechanisms in particular, such as electrically-operated door strikes or door locks, are useful in providing remote or hands-free unlocking operation of a door in a frame, or for providing selective security for items within an area bounded by such a door. In the most general prior art, an electric door release mechanism is powered by a remote electric source, such as an AC grid, connected by a cable, through a transformer, to the unlocking device. The electric door release mechanism may be configured for mounting and operation in the door frame, to engage a cooperative bolt in the door, or the electric door release mechanism may be mounted in the door itself, requiring the cable to pass through the door hinge area in some fashion.
[0005] In some specialized applications wherein a power source such as an AC grid is not available or readily connectable to the electric door release mechanism, it is known to power an electric door release mechanism via a battery incorporated in or immediately proximate the door release system. Such a configuration has the disadvantage that the battery either must be kept charged in some fashion or must be replaced periodically, with risk of security failure if not timely replaced or if the recharging means fails. Further, prior art electric door release mechanisms typically are actuated by a relatively large and powerful linear solenoid or motor. Thus, where hard wiring of the mechanism from a remote power source is not possible, practical or desired, an undesirably large and expensive battery pack for operation of the electric door release mechanism is required.
[0006] What is needed in the art is an electrically operated door device such as an electric door release system wherein the power to a device can be supplied by harvesting of “waste” energy available locally.
[0007] What is further needed in the art is an electric door release system wherein the actuator requires significantly less electric power than in the prior art.
[0008] It is a principal object of the present invention to provide a secure environment wherein security is dependent upon a locally available source of waste energy, and wherein periodic human intervention is unnecessary.
SUMMARY OF THE INVENTION
[0009] Briefly described, a system for powering an electrically operated door device such as an actuator in an electric door release system, in accordance with the present invention, comprises an energy harvester for providing power to the device. The system may include a voltage boost circuit operationally connected to the energy harvester, and a device such as a piezoelectric actuator connected to the voltage boost circuit. The system may further include a power module including a battery, such as a thin film battery, disposed in a circuit between the energy harvester and the voltage boost circuit, and an actuator discharge circuit disposed between the piezoelectric actuator and the power module battery for recycling back to the battery a portion of the power provided to, and not consumed by, the piezoelectric actuator.
[0010] In one aspect of the invention, this system is readily adaptable to an electric door release system wherein an electric door release mechanism is actuated by a piezoelectric actuator powered by an energy harvester. Such an electric door release system in accordance with the present invention comprises: a) a mechanical release mechanism including a piezoelectric actuator for locking or unlocking the mechanism, and b) an energy harvester for providing electric power to the piezoelectric actuator. The energy harvester may be a piezoelectric device or any other type of harvester for collecting waste energy, for example, a stepper motor/generator whose rotor is turned by a door hinge member.
[0011] For use in an environment having variable or relatively low frequency of local waste energy occurrences, a rechargeable battery may be included between the energy harvester and the actuator. Preferably, control circuitry limits the draw on the battery to only the actual amount of power required to energize the piezoelectric actuator. Further, a voltage recycling circuit may be used whereby a substantial amount of the power provided to the piezoelectric actuator may be re-captured and returned to the battery for storage.
[0012] For use in environments having a more continuous level of waste energy available, in another aspect of the invention, the battery may be supplanted by a compound Greinacher-type voltage doubler circuit having substantial electrical capacitance that multiplies the voltage output of an energy harvester up to voltage potential required to energize the piezoelectric actuator.
[0013] In either arrangement, the energy generated by the harvester must be sufficient to keep the battery or capacitors fully charged so as to satisfy future actuator requirements.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] The present invention will now be described, by way of example, with reference to the accompanying drawings, in which:
[0015] FIG. 1 is a block diagram of a system for harvesting and utilizing sporadically available waste energy in accordance with the present invention;
[0016] FIG. 2 is a detailed exemplary circuit diagram of the system shown in FIG. 1 ;
[0017] FIG. 3 is a circuit diagram of a system for harvesting and utilizing continuously available waste energy in accordance with the present invention;
[0018] FIG. 4 is an isometric view of a commercially-available piezoelectric energy harvester;
[0019] FIG. 5 is an edge view of the piezoelectric energy harvester shown in FIG. 4 ;
[0020] FIGS. 6 and 7 are alternate cross-sectional views showing a rotatable actuating sprocket assembly in accordance with the present invention actuating a ballast of a piezoelectric energy harvester;
[0021] FIG. 8 is a cross-sectional elevational view of a mechanical actuator assembly in accordance with the present invention;
[0022] FIG. 9 is an isometric view of a first piezoelectric energy harvester system in accordance with the present invention comprising an energy input portion and an energy harvesting portion;
[0023] FIG. 10 is an isometric view showing the first piezoelectric energy harvester system shown in FIG. 9 ;
[0024] FIG. 11 is an isometric view like that shown in FIG. 10 , showing the energy harvesting module disposed within a hollow door frame;
[0025] FIG. 12 is a schematic cross-sectional view of a second piezoelectric energy harvester system in accordance with the present invention, showing an energy input portion, using a rack gear mounted on a door edge, beginning engagement with an energy harvesting portion;
[0026] FIG. 13 is a view like that shown in FIG. 12 , showing the energy input portion in full engagement with the energy harvesting portion as would occur with the door closed;
[0027] FIG. 14 is a side elevational view of a piezoelectric actuator disposed in a door strike in accordance with the present invention;
[0028] FIG. 15 is an enlarged view of the mechanical operating portion of the door strike shown in FIG. 14 ;
[0029] FIG. 16 is a perspective view of a portion of the keeper shown in FIGS. 14 and 15 ;
[0030] FIG. 17 is an elevational view of a prior art key operated door locking mechanism;
[0031] FIG. 18 is an elevational view showing the door locking mechanism of FIG. 17 modified with a piezoelectric latch in accordance with the present invention;
[0032] FIG. 19 is an isometric view of the mechanism shown in FIG. 18 ;
[0033] FIGS. 20 and 21 are differing isometric views of the unlocking and rotatable portion of the mechanism shown in FIGS. 18 and 19 ;
[0034] FIG. 22 is an elevational view showing the mechanism of FIG. 18 becoming unlocked after activation of the piezoelectric cell;
[0035] FIGS. 23 and 24 are sequential views showing the mechanism of FIG. 18 becoming unlocked by action of a key without activation of the piezoelectric cell;
[0036] FIG. 25 is an isometric view in partial cutaway showing a stepper motor generator harvester having a rotor-mounted pinion gear meshing with a stationary ring gear like that shown in FIG. 11 ;
[0037] FIGS. 26 and 27 are cross-sectional horizontal views of the mechanism shown in FIG. 25 , showing the door in closed and opened positions, respectively;
[0038] FIG. 28 is a door showing, in partial cut away, an energy harvester (exemplary stepper motor generator) mounted on a door hinge to provide energy to unlock the knob lock set mounted on the lock side of the door once an activation switch (not shown) is closed; and
[0039] FIG. 29 is a dual-bridge circuit and stepper motor generator for connection to the micro power module at terminals J 2 .
[0040] Corresponding reference characters indicate corresponding parts throughout the several views. The exemplifications set out herein illustrate currently preferred embodiments of the invention, and such exemplifications are not to be construed as limiting the scope of the invention in any manner.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0041] Referring to FIG. 1 , a system 10 is shown for harvesting and utilizing waste energy to power an electrically operated door device such as a door release actuator in accordance with the present invention. System 10 comprises a device 12 such as a door release actuator 112 ; in one aspect of the invention, as described further herein, device 12 may be for example a low power consumption actuator, such as a piezoelectric actuator 212 . When piezoelectric actuator 212 is used to release a door latch, system 10 may be powered by a power management module 14 that powers a voltage booster 18 for increasing voltage to a level sufficient to energize piezoelectric actuator 212 . Power management module 14 is responsive to a door-release authorization signal 20 and receives power from any waste energy harvester 22 , such as, for example, RF or solar cell harvesters, or other known sources of waste energy as described above, or alternately from a piezoelectric energy harvester 24 which may be configured to harvest door motion energy or door or building vibration energy. In the specific example described below, piezoelectric energy harvester 124 , configured for releasing a door latch, may be incorporated into the hinge region of an electrically secured door for capturing the energy of any and all motion and vibration associated with the opening and closing of the door and other waste energy in the vicinity of the door available for capturing. In yet another specific example described below, a stepper motor generator 724 may be incorporated into the hinge region for capturing the energy associated with opening and closing the door.
[0042] Referring to FIGS. 4 and 5 , piezo transducer 25 that may be used in piezo energy harvester 24 is preferably a Model M-8528-P2, available from Smart Materials Corp., Sarasota, Fla., USA, or a Model Volture V25w, available from Mide Technology Corp, Medford, Mass., USA. Either of these devices develops a damped sinusoidal voltage output when strained in either direction and allowed to vibrate about a fixed end point. Referring to FIG. 2 , the damped sinusoid output from piezo transducer 25 is supplied to a schottky diode bridge rectifier (not shown), the output of which is used to charge a thin film battery (not visible) such as that found in micro power module (MPM) 14 , preferably a Model D-MPM101, available from Infinite Power Solutions, Inc., Littleton, Colo., USA. Additionally or alternatively, an ambient RF or light energy harvester or a stepper motor/generator 724 ( FIGS. 25-29 ), for example a model 17PU-H hybrid stepper motor available from Minebea Motor Corp., Tokyo, Japan, model 17PU-H, can also be used to harvest energy for charging MPM 14 .
[0043] In addition, RF energy 28 a may be captured on a steel door frame and boosted by a charge pump in known fashion to provide a DC output which is then used on the DC charging input of MPM 14 . Similarly, ambient light levels can be detected by a solar cell 28 b such as the Sanyo AM-1454 and the voltage output can be added into the DC charging input for MPM 14 .
[0044] MPM 14 has a regulated output voltage enable circuit which determines the period of time during which the battery is being drained as it supplies current to the voltage boosting circuit. Output energy from MPM 14 can be provided by something as simple as a switch, or by any set of contacts which are closed only after verification of credentials for the person desiring to enter the door. Another function provided by the MPM is to discontinue output voltage if the battery voltage has fallen to less than 60% of its fully charged voltage. Normally, this would never happen as it is the intent of this invention to keep the battery at or near full charge by applying more energy at the recharge inputs than the energy used by the piezo actuator and its control circuitry for each operation of the door.
[0045] Typically, a piezo actuator such as piezoelectric actuator 212 needs voltage on the order of about 225 volts for proper operation. This voltage level is accomplished by employing a capacitor charge device 30 ( FIG. 2 ), preferably a Maxim Max 8622 , available, for example, from Maxim, Sunnyvale, Calif., USA, which converts a low voltage battery output to a voltage level needed by the piezo actuator.
[0046] Numerous piezo cells for use in piezoelectric actuator 212 are available today. A Servo Cell AL2, available from ServoCell, Ltd., Harlow, UK, is found useful as it is a fully integrated unit that provides mechanical blocking of its linear displacement, permitting the piezo actuator to replace an electric solenoid in a slightly modified current production electric strike, as described below. Other piezo actuators, such as the Mide Quick Pack qp20n, available from Mide, Inc., Medfor, Mass., USA, may be used as a means of moving a blocking element to accomplish door unlocking.
[0047] An interesting byproduct of the use of piezoelectric actuator 212 is that once charging of the piezo cell is complete and motion accomplished, it is possible to recapture a percentage of the energy expended in actuating the device by discharging the actuator's capacitance back into the DC charge input of the MPM. Theoretically, one can re-capture via recycle circuit 32 up to 60% of the original energy expended. Thus the actual power consumption of the piezoelectric actuator is substantially reduced.
[0048] The electronic circuitry used to capture the harvested energy and use it to power the piezoelectric actuator consists of two elements—the MPM 14 , and voltage booster 18 .
[0049] Referring to FIG. 2 , MPM 14 contains three connectors, J 2 , J 3 and J 5 . The first two are used to recharge the battery from DC and AC sources respectively. J 2 collects recycled energy 34 from the discharge of piezoelectric actuator 212 . J 3 may be used to collect additional waste energy from a variety of waste energy sources including, for example, collected RF energy 28 a and collected solar energy 28 b . When used to collect energy from piezoelectric energy harvester 24 , 124 or stepper motor/generator 724 , J 3 takes the harvested door motion energy via output 36 . Since energy recoverable from door motion is readily available, it is the primary source of harvested waste energy to recharge the battery. Connector JS is used for input and output signals. Pins 1 and 2 provide under voltage protection to ensure that the battery output never drops below 2.1 volts. Pins 3 and 4 receive enabling signals for the regulated 3.6 volt output provided at pin 7 . Pin 5 is an isolated ground that does not connect directly to the ground of the internal thin film battery. The output voltage from pin 7 MPM 14 provides a low voltage, such as 3.6 volts. Capacitors C 5 and CI filter some of the noise signal created by the switching regulator in the voltage booster. Voltage booster 18 includes a charge device that uses a switching regulator and output transformer to boost an input voltage to an output voltage, for example 200 v. to 250 v., which is needed by the piezoelectric actuator 212 . Resistor R 2 sets the output level which the unit is trying to achieve. In this case, it is set to 237 volts. Resistor R 1 establishes the maximum input draw for the unit which is set as low as possible. Diodes D 1 and D 2 ensure that no back current is supplied to voltage booster 18 when the piezo actuator is discharging. Diode D 3 and resistor R 6 limit the current which can be fed back to recharge the battery through the DC charging input J 2 . Switch 38 , designated SW 1 , applies the re-captured voltage to the battery after the unlock pushbutton is released.
[0050] The timing sequence is then:
[0000] 1) Unlock pushbutton switch 38 is depressed. This opens the re-charge feedback loop and enables the MPM output.
2) Charge device 30 of voltage booster 18 powers piezoelectric actuator 212 until the charge on the actuator reaches the preset level of 237 volts.
3) Unlock push button switch 38 is released and the discharge of piezoelectric actuator 212 is sent back to the battery via circuit 32 .
[0051] Referring now to FIG. 3 , in an environment experiencing a continuously-available, ample source of waste energy wherein an energy harvester can have a continuous Electrical output, it may be possible to use a simplified system 10 ′ for harvesting and using waste energy to power a low power consumption actuator such as piezoelectric actuator 112 . Note that a power module is not required, although the actuator discharge circuit can be used to support the charge on the doubling capacitors. System 10 ′ comprises a piezo harvester, such as for example piezoelectric energy harvester 124 , a voltage boost circuit 18 ′, an operating switch SW 1 38 ′, and a piezoelectric actuator 212 . Voltage boost circuit 18 ′ is preferably a Greinacher-type circuit comprising a plurality of capacitors and diodes as is known in the prior art to boost the harvester output to the voltage potential required to drive the piezoelectric actuator 212 . Obviously, in circumstances wherein waste kinetic energy is not continuously available, a battery and control circuitry as shown in FIG. 2 are required to accumulate waste kinetic energy as it occurs and to energize actuator 212 .
[0052] Referring now to FIGS. 4 and 5 , a piezoelectric transducer 25 is shown, such as the Mide Model Volture V25w cited above. Transducer 25 may be used in piezoelectric energy harvester 24 , 124 . This device converts vibration into electrical energy when the ballast 125 , mounted on base plate 127 which also contains the piezo device, is flexed in either direction from the rest position 129 . Transducer 25 has good elastic attributes that allow it to deflect 131 from center up to about 0.25 inches on either side of rest position 129 .
[0053] Referring now to FIGS. 6 through 8 , a mechanical actuator assembly 200 is shown that may be used in conjunction with piezoelectric energy harvester 124 . Mechanical actuator assembly 200 comprises a base plate 202 and stanchion 204 for rotatably supporting a rotatable actuating sprocket assembly 206 . Sprocket assembly 206 comprises a yoke 208 mounted on a shaft 210 journalled in stanchion 204 and includes a plurality of actuators 211 , exemplarily four, mounted for both pivoting and translating in yoke 208 as described below. Each actuator 211 is provided with a rounded nose 214 , rides in a first radial slot 216 formed in yoke 208 , and is pivotably pinned by a pin 218 into a second slot 220 formed in yoke 208 . Each actuator 211 captures a bias spring 222 in second slot 220 such that each actuator is urged after perturbation to return to a rest position 224 as shown in FIG. 8 . Thus, each actuator 211 during rotation of sprocket assembly 206 and sequential engaging with, and disengaging from, ballast 125 of a piezoelectric energy harvester 124 is free to move rotationally on pin 218 in either direction ( FIGS. 6 and 7 ) and to move translationally radially in first and second slots 216 , 220 in response to being perturbed by rotation of assembly 206 in either direction as described below.
[0054] Referring now to FIGS. 9 through 11 , a first piezoelectric energy harvester system 300 in accordance with the present invention comprises an energy input portion 302 and an energy harvesting portion 304 .
[0055] Energy input portion 302 comprises a door hinge 306 mountable to a door 308 in door frame 310 to cause the door 308 to swing in the frame 310 . A hinge pin 312 extends beyond the leaves 314 , 316 of hinge 306 and fixedly supports a drive member such as a hinge pin spur gear 318 . Hinge pin 312 is attached to the door-mounting leaf 316 of hinge 306 such that pin 312 and gear 318 remain fixed and stationary with respect to door 308 but rotate about hinge pivot axis 320 when door 308 is swung on hinge 306 .
[0056] Energy harvesting portion 304 comprises a piezoelectric energy harvester 124 as shown in FIGS. 4 and 5 mounted via a bracket 322 to base plate 202 of a mechanical actuator assembly 200 . Mechanical actuator assembly 200 comprises base plate 202 and first and second stanchions 204 for rotatably supporting a rotatable sprocket assembly 206 . Sprocket assembly 206 comprises first and second yokes 208 fixedly mounted on a shaft 210 journalled in stanchions 204 . First and second yokes 208 are opposed on shaft 210 and are crenellated to be mutually out of phase by 45° such that sprocket assembly 206 provides 8 actuators 211 for engaging harvester ballast 125 . Shaft 208 extends beyond stanchion 204 to support a driven member such as capture (pinion) gear 324 meshed with hinge pin (spur) gear 318 .
[0057] Energy harvesting portion 304 defines an energy harvesting module that preferably includes a cover (not shown) for protecting harvester 124 and sub-assembly 206 from the environment, as well as to reduce the noise of engagement of the gears and the actuators with the ballast.
[0058] An advantage of piezoelectric energy harvester system 300 is that the driver/driven ratios may be selected to maximize energy harvest for a particular application. Further, the mass of ballast 125 may be selected to match the anticipated door velocity and thus optimize the resonance periods between ballast/actuator engagements to maximize energy output of harvester 124 .
[0059] Referring now to FIGS. 10 and 11 , an exemplary installation of harvester system 300 is shown. Energy input portion 302 is mounted to an edge of door 308 , and energy harvesting portion 304 is mounted within a hollow frame 310 which is slotted 326 to provide access for gear 318 to gear 324 . Energy is captured by harvester 124 during opening and closing motions of the door in the frame.
[0060] Referring now to FIGS. 12 and 13 , a second piezoelectric energy harvester system 300 ′ in accordance with the present invention comprises an energy input portion 302 ′ and the energy harvesting portion 304 described above. Only capture pinion gear 324 of portion 304 is shown.
[0061] System 300 ′ harvests kinetic energy from the door-latch side of a door 308 ′ mounted in a hollow frame 310 ′, as opposed to embodiment 300 which harvests energy from the hinge side. In system embodiment 300 ′, energy harvesting portion 304 is mounted within frame 310 ′, and energy input portion 302 ′ includes a drive member such as linear rack gear 318 ′ mounted to the beveled edge of door 308 ′ for engaging the driven member (pinion gear 324 ) to drive energy harvesting portion 304 as in the first system embodiment 300 . It will be seen that energy is harvested both in opening and in closing door 308 ′.
[0062] Referring to FIGS. 10 and 12 , with respect to systems 300 and 300 ′, to reduce cost and noise, it is understood and contemplated by this invention that drive gears 318 , 318 ′ can be replaced with friction wheels having, for example, a resilient contact surface 330 and driven gears 324 , 324 ′ can be replaced with a friction wheel or a friction rack having, for example, a mating resilient surface 332 .
[0063] Referring now to FIGS. 14 through 16 , as one embodiment, an electric strike portion 400 - 2 of an electric door strike system in accordance with the present invention comprises an electric strike 402 , for example, a Model 5000 available from Hanchett Entry Systems, Inc., Phoenix, Ariz., USA, modified as described below to include a piezoelectric actuator 212 in place of a standard linear electric solenoid (not shown). For simplicity and clarity, only the mounting and actuation portion of strike 402 are shown.
[0064] Strike 402 comprises a formed metal frame 404 supporting piezoelectric actuator 212 having a shaft 406 extending longitudinally therefrom. Shaft 406 includes an actuation portion 408 extending through a linear bearing 410 mounted in frame 404 . Actuation portion 408 includes a collar 412 to limit axial motion of shaft 406 away from actuator 212 by engagement with a support bracket 414 also mounted on frame 404 . Actuation portion 408 further includes an annular groove 416 having a beveled side defining a shaft engagement slope 418 for receiving a keeper 420 having a mating engagement slope 422 . Keeper 420 is a blocking link in the linkage releasing or locking a latch (not shown) in strike 402 .
[0065] Referring to FIG. 16 , keeper 420 includes pivot hole 424 for mounting to strike 402 and an arcuate slot 426 concentric with the axis of pivot hole 424 . The lands on either side of slot 426 are tapered to form engagement slope 422 as shown in FIGS. 14 and 15 .
[0066] Referring again to FIG. 15 , shaft 406 is shown in the blocking position wherein keeper 420 blocks the linkage from activating to unlock the latch. Shaft 406 is biased to the right in FIG. 15 by one or more bias springs (not visible). The shaft bias springs are sufficiently powerful that, in combination with the de-energized piezo cell, the keeper is maintained in the locking position against a latch-opening force sufficient to resist unwanted unlocking of the lock, as for example, up to at least 1000 pounds of latch-opening force. When the piezo cell in actuator 212 is energized, the cell actuates a blocking element, permitting shaft 406 to move to the left, allowing keeper 420 to rotate to move groove 416 farther into slot 426 , in which position keeper 420 no longer blocks the linkage and the latch is thus unlocked. In this condition, a relatively small manual force applied to the latch as by a person attempting to open the door is sufficient to displace the shaft to the left and allow the keeper to be forced into the unlocking position by engagement of the engagement slopes 418 , 422 . Conversely, when the piezo cell is de-energized, the combined force of piezo cell expansion and the bias springs displaces the shaft to the right, causing the keeper to be returned via engagement slopes 418 , 422 to the locking position shown in FIGS. 14 and 15 .
[0067] While energy harvester systems 300 and 300 ′ are shown utilizing sprocket assembly 206 having an array of spring-loaded actuators 212 for purposes of absorbing some of the contact forces that would be imparted on ballast 125 , it is understood that, within the scope of the invention, sprocket assembly 206 may be simply a wheel having a select number of radial teeth for making contact with ballast 125 .
[0068] Referring to FIG. 17 , an exemplary, prior art handle-lock set 500 , for example, a commercially available key-in-knob-lock, comprises a hub 502 having first and second connecting posts 504 extending therefrom for receiving screws (not shown) extending through a door and bezel (not shown). A locking shaft 506 and latch engaging shaft 508 extend through an opening in hub 502 . Locking shaft 506 is connected to key 530 but is turnable independently of latch engaging shaft 508 which is attached to knob 509 . Cooperative with locking shaft 506 is a floating locking tab 510 having spaced-apart first and second locking tangs 512 , 514 straddling upper connecting post 504 within locking ring 515 . As shown below in FIG. 21 in connection with the disclosure of the present invention, a cam plate 516 having an angled slot 518 is mounted to locking shaft 506 . A pin 520 attached to locking tab 510 extends through slot 518 . Slot 518 is formed such that upon rotation of locking shaft 506 (clockwise in FIG. 21 ; counterclockwise in FIG. s 17 ), locking tab 510 is moved inwardly along a radius of hub 502 until tangs 512 / 514 no longer straddle connecting post 504 and can clear locking ring 515 , permitting knob 509 and latch engaging shaft 508 to be rotated, thereby actuating a door latch (not shown) to open the door (not shown).
[0069] Referring now to FIGS. 18-21 , in a handle-lock set 600 in accordance with the present invention, floating locking tab 510 is modified to define a novel floating locking tab 610 in accordance with the present invention. Prior art tang 512 is retained, but prior art tang 514 is replaced by assembly 623 comprising a piezoelectric actuator 622 and a domed plunger 624 . Locking ring 515 is modified to define a novel locking ring 615 having a ramp 626 for engaging domed plunger 624 in the locked state. Piezoelectric actuator 622 is preferably of the type AL-2, available from Servocell Ltd., Harlow, UK.
[0070] Complete locking and unlocking control is still furnished by either the key 530 on the interior side or the thumb turn (not shown) on the exterior side. Note: The key and thumb turn may be positioned on respective interior and exterior sides as may be desired in any particular application.
[0071] When the lock has been placed in the locked state by either of the above, the locked state may be overridden in one of three ways: by energizing of actuator 622 , by rotation of key 530 or the use of thumb turn, not shown.
[0072] Referring to FIG. 22 , when piezoelectric actuator 622 is energized, handle/knob 509 may be turned in one direction (unidirectional) to open the door despite the door's being mechanically key-locked. In its un-energized state, piezoelectric actuator 622 remains rigid with domed plunger 624 extended as shown in FIG. 18 . Energizing of actuator 622 removes rigid support for plunger 624 . Torque on handle/knob 509 ( FIG. 19 ), locking shaft 506 , and floating tab 610 urges the dome of plunger 624 against ramp 626 , causing plunger 624 to be forced into assembly 623 . When the plunger has cleared the ramp, tab 610 may be turned as shown, unlocking the mechanism. Note that cam plate 516 is not activated and tab 610 has not been moved radially inwards of hub 502 . Note also that handle/knob 509 can be turned in only one direction to act against piezo actuator 622 . Turning the handle/knob in the other rotational direction, even with piezoelectric actuator 622 energized, will cause locking tang 512 and rotation of knob 509 to be blocked by post 504 . In a variation of the embodiment shown in FIGS. 22-24 , and referring to FIG. 23 , locking tang 512 may be replaced with a second piezo actuator assembly 623 and ring 615 may be further modified with a second mirror-imaged ramp 626 on the opposite side of post 504 . With this variation, handle/knob 509 may be turned in either rotational direction (bi-directional) to open the door upon energizing the actuators despite the door's being mechanically key locked.
[0073] Referring now to FIGS. 23 and 24 , handle-lock set 600 may also be unlocked conventionally by the key. As described above, when key 530 and locking shaft 506 are turned, cam plate 516 urges tab 610 radially inwards of hub 502 such that tang 512 and plunger 624 , or a pair of plungers 624 , no longer straddle connecting post 504 ( FIG. 23 ), allowing latch engaging shaft 508 to be rotated ( FIG. 24 ).
[0074] Referring now to FIGS. 25 through 27 , a further embodiment 700 of an energy harvester is shown. A stationary drive member such as drive gear 718 is mounted to a fixed hinge pin 712 of a door hinge 702 mounted on a frame 710 . An energy harvester mounted on a door 308 in the form of a stepper motor/generator 724 is provided with a driven member such as pinion gear 704 in meshing relationship with drive gear 718 . As door 308 is rotated in either the opening or the closing direction ( FIG. 27 ) on hinge pin 712 , pinion gear 704 is rotated causing lobes of the magnetic rotor (not visible) of stepper motor/generator 724 to serially pass by and excite the coils (not visible) within the stepper motor in known fashion, generating an output series of two-phase sinusoidal signals along wire leads 726 that may be captured as stored electrical energy by the thin film battery in power management module 14 ( FIGS. 1 and 2 ). Preferably, the sinusoidal signals are rectified by passage through a pair of bridge rectifiers 730 shown in FIG. 29 attached to the DC charging input of MPM 14 at connector J 2 ( FIG. 2 ).
[0000] To reduce cost and noise, it is understood and contemplated by this invention that drive gear 718 can be replaced with a friction wheel having, for example, a resilient contact surface 730 and driven gear 704 can be replaced with a friction wheel having, for example, a mating resilient surface 732 ( FIG. 26 ).
[0075] Referring to FIG. 28 , in a door 308 , such as for example a Rite Door manufactured by Adams Rite Co. Pomona, Ca, an energy harvester (exemplarily a stepper motor/generator 724 in accordance with the present invention) is coupled to a micro power module 14 , as described above, and a piezoelectric door lock (exemplarily a key-in-the-knob lock set 600 in accordance with the present invention as shown in FIGS. 18-24 ). While stepper motor/generator 724 is shown exposed through surface 309 of door 308 , it is understood that motor/generator 724 and interconnecting wires may be completely confined between opposing door surfaces 309 , 311 , of the exemplary door so that motor/generator 724 is not readily visible or readily accessible from either surfaces.
[0076] While the invention has been described by reference to various specific embodiments, it should be understood that numerous changes may be made within the spirit and scope of the inventive concepts described. Accordingly, it is intended that the invention not be limited to the described embodiments, but will have full scope defined by the language of the following claims. | A piezoelectric energy harvester system for collecting kinetic energy is provided, wherein the kinetic energy is converted into electrical energy, and wherein at least a portion of the converted electrical energy is utilized to operate a load. The system comprises an energy input portion and an energy harvesting portion. The energy input portion includes an input member configured to be actionable by an outside force. The energy harvesting portion includes a capture member, a sprocket portion, and a piezoelectric energy harvester. The capture member is adapted for receiving mechanical input from the input member. The sprocket portion is disposed for movement with the capture member. The sprocket portion includes at least one radially disposed sprocket actuator configured for making contact with and exciting the piezoelectric energy harvester. The piezoelectric energy harvester is excited by the contact to produce the kinetic energy. | 4 |
CLAIM OF PRIORITY
[0001] This application is a claims priority from U.S. provisional patent application 61/561,320, filed on Nov. 18, 2011, the contents of which are fully incorporated here by reference.
FIELD OF THE INVENTION
[0002] The invention relates to a multi-layered, easy-to-use medical tape, and more particularly to a medical tape that prevents injuries caused by needles, especially the needlestick injuries to healthcare professionals when they are trying to make an injection or perform a surgery. This invention also provides a device that holds a needle more firmly in place during surgery or infusion and folds over the needle once it has been removed from the patient while the needle is being transported and disposed.
BACKGROUND OF THE INVENTION
[0003] Needlestick injuries are common to healthcare workers, especially those who perform injections and surgeries regularly. According to data collected from 63 hospitals by the United States Occupational Safety & Health Administration (OSHA), the overall rate of needlestick injuries is 27 per 100 occupied beds annually. While nurses had the most frequent exposures (49.7 percent), physicians ranked second (12.6 percent). Such injuries are probably also frequent occurrences for non-professionals who take up the duty to perform injections in the course of taking care of himself/herself or a loved one. To simplify the description, the present application will refer mainly to healthcare professionals, while it should be clear that the invention will benefit anyone who may be subjected to medically related needlestick injuries.
[0004] In addition to the initial physical wounds, needlestick injuries can have serious consequences because the person injured may be exposed to pathogens or other contaminants that may result in grave secondary health risks. Such pathogens include but are not limited to: hepatitis B virus (HBV), hepatitis C virus (HCV), and human immunodeficiency virus (HIV). The danger that suffering a needlestick would induce infection is real and threatening to the healthcare professionals.
[0005] Besides the possibility of physical injuries and infections, a healthcare professional endures significant psychological pressure when he/she is concerned with needlestick injuries. The prospect that he/she might be injured may impair the concentration that is needed for the competent performance of a medical procedure. In addition to the psychological toll before injury, a person suffered from needlestick injury will be forced to endure the agonizing period waiting for test results as to whether a life-altering infection has occurred. The overall mental distress that may be caused by needlestick injuries is impossible to be ignored.
[0006] Being careful with needle and syringe operation can only help the person conducting an injection, infusion, or surgery to a certain extent. Sometimes it is inevitable that a slip of hand or occasional absentmindedness will occur and severe risks will result from a seemingly insignificant needlestick wound. The current invention helps to prevent needlestick injuries to healthcare professionals by providing a medical tape that cannot be penetrated in normal medical care operations. Nurses, physicians, and other healthcare workers can wear the medical tape at the necessary positions or apply the tape to certain locations that may subject the healthcare worker to possible needlestick injuries. With the tape properly worn or applied, the healthcare worker no longer needs to continue worrying about injuries and can focus on the task at hand.
[0007] Previous efforts to prevent needlestick injuries focus on using universal precautions, engineering and work practice controls, and personal protective equipments. The safety devices generally involve modifications to the syringes and needles, such as the following patent and patent publication:
[0008] European Patent EP 2331167A1 discloses an anti-needlestick system comprising a housing assembly. The assembly has a body portion. The body portion has distal and proximal ends, a cylindrical extent, and upper and lower sections. The distal end has a first aperture. The proximal end has a second aperture. The upper section has a lower edge and the lower section has an upper edge. A pair of flexible hinge portions is provided. The upper ends are coupled to the upper section. The lower ends are coupled to the lower section. The hinge portions are adapted to allow movement between closed and open orientations. Handling elements are formed with the main body portion. The handling elements include an upwardly extending projection located on the upper section essentially coplanar with the distal end to facilitate one handed utilization of the system.
[0009] U.S. Patent Publication No. US20050267410A1 discloses a needlestick prevention device for an injection device ( 1 ) having a hollow needle ( 2 ) comprises a sheath having a first member ( 9 ) for attachment to the injection device ( 1 ) and a second member ( 10 ) slidable longitudinally relative to the first member ( 9 ) to expose or to cover the needle ( 2 ), and spring means ( 11 ) biasing the second member ( 10 ) to cover the needle ( 2 ). The first and second members ( 9 , 10 ) have inter-engaging guide means ( 13 ) and locking means ( 14 ), including a first guide part ( 23 ) operative to allow free longitudinal sliding movement of the second member ( 10 ) relative to the first member ( 9 ), and a second guide part ( 24 ) operative on movement by manual relative rotation of the first and second members ( 9 , 10 ) and following release of a force urging the second member ( 10 ) to expose the needle ( 2 ). The spring means ( 11 ) urges the second member ( 10 ) to cover the needle ( 2 ) and to operate the locking means ( 14 ) to retain the second member ( 10 ) covering the needle ( 2 ). This allows free movement of the second member ( 10 ) in the first guide part ( 23 ), allowing for filling of the syringe ( 1 ), but then automatic sheathing and locking when the user simply twists the second member ( 10 ) relative to the first ( 9 ).
[0010] These modifications to needles or syringes are generally expensive and relatively more difficult to use. Moreover, they may not be appropriate for the specific medical procedure that is required for a particular patient. A more “defensive” approach may reduce such concerns. The healthcare professional may wear certain protective device on his/her hand that does not operate the needle or syringe. The following two patents serve as examples for such approaches.
[0011] U.S. Pat. No. 5,953,751 discloses a needlestick resistant glove for surgical and other medical uses including a flexible and elastic web which fits the user's hand. In one embodiment the web is partly covered by custom-fitted curved plates. The flexible web areas between the plates comprise hemispherical or disk protrusions. In another embodiment, without plates, the protrusions on the web are disks and the areas between the disks are covered by other disks.
[0012] U.S. Pat. No. 5,187,815 discloses a glove for use by medical personnel which is adapted to help prevent accidental injuries when handling needles includes a first discrete layer of flexible material which has a pore size smaller than the diameter of a needle. The first layer forms a glove with an optional opening in the fingerprint area of the index finger stall and middle finger stall. The glove also includes a second discrete layer of flexible material which also has a pore size which is smaller than the diameter of a needle. This second layer is permanently attached to selected areas of the first layer. The selected areas comprise all of the thumb stall, and lateral sides of the index finger stall and middle finger stall. Preferably, the fingernail region is not covered by the second layer and backsides of the first distal joint portion of the index and middle finger stall are covered. A V-opening for the back side of the glove includes two distinct fastening devices. A third discrete layer of corrugated metal foil is optionally provided in the selected areas. Methods for sterilization and disinfecting are also provided.
[0013] These inventions, however, are rather limited in another perspective because they both have gloves as embodiments but a glove cannot be worn on any other part of the body. While the hand not operating the needle may be subjected to possible injuries, other parts of the body can also be needlesticked. The current invention addresses such inflexibility by introducing a needle-resistant medical tape that can be worn on any part of the body.
[0014] In conclusion, various implements are known in the art, but their structures are distinctively different from the current invention. Moreover, the prior art fails to address all of the problems solved by the invention described herein. One embodiment of this invention is illustrated in the accompanying drawings and will be described in more detail herein below.
SUMMARY OF THE INVENTION
[0015] As indicated above, needlestick injuries serve as a significant threat to the safety and welfare of the healthcare workers. Needlestick injuries can be caused by many kinds of injections, infusions, and operations. Accordingly, many kinds of needles, such as but not limited to syringe needles, infusion needles, and electrode needles, may cause needlestick injuries. The situations surrounding the injuries vary significantly. Some injuries involve errors in medical procedures; others may prove to be the result of a lack of protection. The most common needlestick injury may be caused by the mishandling of injections with a syringe needle. However, some injuries are caused by more exceptional incidents. One such example is the needlestick injuries that occur during spinal surgeries. In spinal surgeries, the healthcare professionals usually need to set up several electrode needles for monitoring the patient's neuronal activities. While these needles may cause injury to the healthcare worker when they are first being applied, they may cause further damages when they are dislodged from the patient's body, or even when movements in the surgery make the needles protrude out of the patient's skin. Since the electrode needles need to be affixed to the patients for a long time, the chances of needlestick injury in spinal surgeries are not infrequent.
[0016] The current invention discloses a medical tape that addresses the problem of needlestick injuries. The medical tape has a multi-layered structure that can protect a user of the medical tape from needlestick injuries. By wearing the medical tape at appropriate positions or applying the medical tape to likely places that might be subject to penetration, the healthcare work may prevent needlestick injuries and reduce the likelihood of secondary risks. Moreover, the medical tape disclosed here may serve multiple purposes besides blocking needlestick penetration. The medical tape is sticky on one side so that it may be used to fix an inserted fusion or surgery needle in place to prevent incidental dislodging and further injuries. In addition, the medical tape may be flexible enough to encapsulate a used needle before it is being disposed in a proper receptacle.
[0017] Various devices, apparatus, and mechanisms have been developed to reduce the likelihood of needlestick injuries. Since the medical tape described herein takes a defensive approach to needlestick injuries, there is no need to modify the structure of the needles or the apparatus applying the needles. Moreover, unlike the needlestick-proof gloves described above, the medical tape can be cut into any shape, applied anywhere, and used in a very flexible manner.
[0018] The medical tape disclosed in the current invention has a multi-layered structure, comprising a non-stick layer, a foam layer with a sticky side, at least one needle-resisting layer, and a top layer to provide additional resistance, comfort, coverage, color, and flexibility. The materials used for the medical tape are relatively inexpensive, making the medical tape affordable and boosting its availability. The specific material chosen for the needle-resistant layer may vary in a certain degree, allowing the medical tape to be available in different forms that may reflect the actually usage of the medical tape. The shape and size of the medical tape may vary, allowing it to be applied to different part of the body to fit different needs in injections, infusions, and operations.
[0019] It is an object of the present invention to provide a medical tape that reduces the needlestick injuries to healthcare professionals and other non-professional caregivers.
[0020] It is another object of the present invention to provide a medical tape that is easy to use and easy to put on and take off.
[0021] Yet another object of the present invention is to provide a medical tape that can be worn on any part of the user's body.
[0022] Still another object of the present invention is to provide a medical tape that allows the user to choose how much tape should be worn.
[0023] Yet another object of the present invention is to provide a medical tape that is inexpensive and disposable after use.
[0024] Still another object of the present invention is to provide a medical tape that is easily adjustable.
[0025] Yet another object of the present invention is to provide a medical tape that may fix an inserted needle in a patient's body.
[0026] Still another object of the present invention is to provide a medical tape that may be wrapped around a needle before it is being disposed.
[0027] Still another object of the present invention is to provide a medical tape that is multiple layered and protects the user from injuries that can be caused by different kinds of needles.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] FIG. 1 is a cross section view of a preferred embodiment of the medical tape.
[0029] FIG. 2A is a top view of a preferred embodiment of the medical tape.
[0030] FIG. 2B is a top cut-away view of another embodiment of the medical tape.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0031] The preferred embodiments of the present invention will now be described with reference to the drawings. Identical elements in the various figures are identified with the same reference numerals.
[0032] Reference will now be made in detail to embodiment of the present invention. Such embodiments are provided by way of explanation of the present invention, which is not intended to be limited thereto. In fact, those of ordinary skill in the art may appreciate upon reading the present specification and viewing the present drawings that various modifications and variations can be made thereto.
[0033] FIG. 1 shows a cross section view of a preferred embodiment of the medical tape, which has multiple layers. Shown is the medical tape 1 having a first layer 10 having a first side 110 and a second side 120 ; a second layer 20 having a first sub-layer 210 and a second sub-layer 220 , which is needle resistant, a third layer 30 and the top covering layer 40 .
[0034] To show the different layers more clearly, the thickness of the layers shown in FIG. 1 is not proportional. Generally, the medical tape 1 , as a whole, should not be too thick to prevent smoothly conducting the procedures that are needed. While the thickness of the first layer 10 may be 0.1 to 10 millimeters (mm), the overall thickness of the second layer may be 0.1-5 mm. In the preferred embodiment, while the first layer 10 is about 1.59 mm ( 1/16 inch) thick, the first sub-layer 210 of the second layer 20 is about 0.19 mm (0.0075 inch) thick, and the second sub-layer 220 of the second layer 20 is also about 0.19 mm (0.0075 inch) thick. It should be noted that as long as the thickness of the layers does not prevent the effective blocking of most of the common needlestick penetrations, the thickness is acceptable.
[0035] The first layer 10 provides a soft touch for the medical tape 1 , allowing the tape to be worn comfortably. In certain circumstances, the first layer 10 may also absorb pressure and reduce the likelihood that a needle will penetrate the medical tape 1 . The first layer 10 has a first side 110 and a second side 120 . The first side 110 is designed to be sticky and may attach to the skin of a patient or any other surfaces that may need protections. In the preferred embodiment, the adhesive used for the first side 110 is acrylic. However, it should be noted that any adhesive is acceptable as long as it is non-toxic and the medical tape 1 can be attached firmly and removed without harming the patient. When the medical tape 1 is not in use, the first side 110 of the first layer 10 is attached to the third layer 30 . The third layer 30 of the medical tape 1 may be made from non-sticky paper, allowing the medical tape 1 to be handled without attaching to its surroundings before the medical tape 1 is in use. The third layer 30 may be removed before the medical tape 1 is applied so that the first side 110 of the first layer 10 is exposed and the medical tape 1 may be attached to any desirable site.
[0036] Since the first side 110 is sticky, the medical tape 1 may be used to fix an inserted needle to a patient's body. During an infusion or some particular surgery, such as the spinal surgery using electrode needles, there is a need to assure that the inserted needle to stay in place, most often for a long period of time, such as several hours. The medical tape 1 , in such circumstance, may serve to fix the needle in place by being taped to the hold part of the needle to the skin, not allowing it to slip out of its intended anatomical position. Furthermore, the medical tape 1 may protect the patient and staff while the patient is being moved, transported, or restrained.
[0037] Though the first layer 10 does not need to be completely needle resistant, it may reduce the power of penetration when a needlestick protrusion is applied to it, helping to reduce the chances of injury. In spinal surgeries, for example, the electrode needles that are attached to a patient's body may penetrate the patient's skin and cause injury to the healthcare professional. If the medical tape 1 is applied to the patient's skin, the first layer 10 may be the first line of defense against a possible penetration. The first layer 10 , therefore, serves to provide the initial blockade to needlestick penetration by reducing the needle's force.
[0038] The first layer 10 may be made from soft and flexible material that may absorb pressure. A preferred material is flexible foam, such as Polyurethane. In the preferred embodiment, the first layer 10 is made from polyurethane foam tape provided by 3M, Inc. Aside from flexible foam, the first layer 10 may be made from many kinds of materials such as flexible plastic, including but not limited to Ethylene Vinyl Acetate (EVA), flexible PVC, High Density Polyethylene (HDPE), Expanded Polypropylene (EPP), and Ethylene Vinyl Acetate (EVA). As long as the material is non-toxic, flexible, and pressure absorbing, it may be made into the first layer 10 .
[0039] The second layer 20 is the needle-resistant layer of the medical tape 1 . While the first layer 10 may reduce the pressure from a protruding needlestick, the second layer 20 may serve as the main blockade to stop the needlestick from penetration. The second layer 20 is tightly attached to the first layer 10 , with a method that may vary according to the materials used to make the first layer 10 and second layer 20 . For example, the first layer 10 and second layer 20 may be glued, molded, or co-molded to ensure close attachment.
[0040] While FIG. 1 shows the second layer 20 to be a two-layered structure having the first sub-layer 210 and the second sub-layer 220 , it should be noted that the needle-resistant second layer 20 may be one single layer or a combination of a number of sub-layers. A single layer structure is generally easier for manufacturing purposes. However, a multi-layered design may enhance the capacity of the second layer 20 to block needlestick penetrations. The sub-layers of the second layer 20 may be glued, molded, or co-molded to ensure close attachment.
[0041] The second layer 20 may be made from flexible, semi rigid, or rigid plastic or other materials that are needle resistant. In the preferred embodiment, the second layer 20 is made of fabrics or sheets based on steel core yarn technology, such as the Rhinoguard™ material. Moreover, other materials that may be used include but are not limited to: fiber composite fabrics such as the TurtleSkin® material, silicone, wood, high density rubber, sheet metal such as aluminum, Polyethylene terephthalate (PET)ABS, Polycarbonate, Noryl™, PVC, Polystryrene, ABS/PVC, PVC/Acrylic, Polysulfone, Acrylic, Polyethylene, and Kydex™. Other materials that may be used to make the second layer 20 include high density fabrics or joint sheets with special coating as blocking elements. One alternative material is the SuperFabric® material that is needle-resistant and flexible. The key requirement for the material to make the second layer 20 is it must be needle resistant and can be easily molded into different thickness, sizes, and shapes.
[0042] The sub-layers of the second layer 20 may be made of same of different materials. For example, two different kinds of materials, such as steel core yarn sheets, PET and SuperFabric®, may be used to make the two sub-layers that combine to form the second layer 20 . Nevertheless, the sub-layers may be made from the same material. The second layer 20 preferred embodiment shown in FIG. 1 has two sub-layers 210 and 220 that are both made of PET. As long as the sub-layers are tightly attached and work to block needlestick penetration, the choice of materials may be rather flexible.
[0043] FIGS. 2A and 2B show a top view of two preferred embodiments of the medical tape 1 . In FIG. 2A , the medical tape 1 is shown as a rectangular shape, while the only visible portion is a top covering layer 40 . All the other layers are the same size as the covering layer 40 . FIG. 2B is a top cut-away view that shows the medical tape 1 having the top covering layer 40 , the second needle-resistant layer 20 , and the first layer 10 . The covering layer 40 is made partially transparent to make the first layer 10 and second layer 20 visible.
[0044] The medical tape 1 may be provided as different shapes. The most common shape is what is shown in FIG. 2A and 2B , as square or rectangular pieces. However, the medical tape 1 may be made to be round, oval, triangular, or any other shape that might fit the needs for a specific operation. As an example, the medical tape 1 may be in a butterfly shape that may be suitable for attachable to the fingers or the palm edge of a user.
[0045] The medical tape 1 may be provided as different sizes. In general, since the medical tape 1 may be cut into smaller pieces or a few tapes may be aligned to provide bigger coverage, the size of the medical tape 1 may be flexible. In particular, the square medical tape 1 shown in FIG. 2A has a size of 5.08 cm (2 inches) by 5.08 cm (2 inches). As long as it fits the requirement of the medical procedure that is being performed, the medical tape 1 may be any size that is practical.
[0046] While FIG. 2A shows all the layers of the medical tape 1 to be the same size and shape, and being arranged in a completely overlapping format, it should be noted that the different layers may be somewhat different in their parameters to facilitate the application of the medical tape 1 . Take FIG. 2B as an example, the second layer 20 is not a complete big piece. In a top cut-away view, FIG. 2B shows the second layer 20 being divided into smaller patches than the first layer 10 and the covering layer 40 . In FIG. 2B , the second layer 20 is arranged in rectangular patches that still covers the vast majority of the overall area. Such a design allows easier bending and cutting of the medical tape 1 because second layer 20 , compared with the other layers, is less flexible and more difficult to cut. The arrangement is necessary especially when the second layer 20 is made of rigid material such as Polycarbonate. This design, however, only minimally impacts the capacity of the medical tape 1 to block needlestick penetration because the needle-resistant second layer 20 still covers more than 90 % of the entire medical tape 1 .
[0047] Overall, the medical tape 1 is preferred to be flexible and may be easily wrapped around an object. The contributing factors include what material the second layer 20 is made of and how the second layer 20 is arranged. By adopting a fragmented format for the second layer 20 , the medical tape 1 may be flexible even if the material making the second layer 20 is rigid. Nevertheless, plenty of materials, such as the SuperFabric®, may ensure that the medical tape is both needle resistant and flexible.
[0048] Being flexible allows the medical tape 1 to serve another purpose. When an infusion or a surgery is completed, the medical tape 1 may be wrapped around the needle that is no longer needed and prevent accidental injuries. The medical professional may take the needle encapsulated in the medical tape 1 and dispose the needle in a proper receptacle, without worrying about incidental injuries during the transporting and disposal processes.
[0049] As shown in FIGS. 1 and 2 , the medical tape 1 may comprise a top covering layer 40 . The top covering layer 40 may be directly attached to the second layer 20 . The top covering layer 40 provides coverage, comfort and/or stability. In one embodiment, the covering layer 40 may serve the same function as the first layer 10 , absorbing pressure and reducing the likelihood that a needle will penetrate the medical tape 1 . The top covering layer 40 may be made from any material that is flexible and can be made into a thin layer. In the preferred embodiment, the covering layer 40 may be made from polyurethane foam. Aside from flexible foam, the first layer 10 may be made from many kinds of materials such as flexible plastic, including but not limited to Ethylene Vinyl Acetate (EVA), flexible PVC, High Density Polyethylene (HDPE), Expanded Polypropylene (EPP), and Ethylene Vinyl Acetate (EVA). As long as the material is non-toxic, flexible, and pressure absorbing, it may be made into the first layer 10 .
[0050] It is also preferred that the top covering layer 40 is able to receive printing or marking. In one preferred embodiment, the top covering layer 40 may have color and may be printed or inscribed. On the top covering layer 40 , a manufacturer of the medical tape 1 may print a logo, a sign, a warning, or any content that is proper. For example, a warning to prevent needlestick injuries can be printed to alert the medical professional to stay focused during a procedure. In addition, the color and inscriptions on the top covering layer 40 may provide distinctions between different types of medical tapes suitable for different procedures, ensuring that the most effective medical tape 1 is used.
[0051] Although this invention has been described with a certain degree of particularity, it is to be understood that the present disclosure has been made only by way of illustration and that numerous changes in the details of construction and arrangement of parts may be resorted to without departing from the spirit and the scope of the invention. | The current invention discloses an inexpensive, easy to use medical tape that reduces the chance of needlestick injuries. The medical tape comprises of multiple layers including a first layer made of pressure absorbing materials such as flexible foam, and a needle resistant layer. The medical tape may further comprise a third layer made preferably of non-stick paper and a covering layer made preferably of vinyl. A medical professional making injections or performing an operation may cover his/her body or a patient's body with the medical tape to prevent needlestick injuries. Moreover, the medical tape may come in various shapes and sizes and may be cut into suitable pieces for different procedures. | 0 |
BACKGROUND OF THE INVENTION
[0001] This invention relates generally to the laboratory information management systems and specifically to the laboratory routines performed using computational infrastructure. The invention enables the digital business rules and implementations of the Standard Operating Procedures (SOPs) to perform the quality control and quality assurance. An SOP is an organizationally approved series of instructions for the laboratory scientists to follow to perform the laboratory routines.
[0002] Recent advances in the bioscience, including genomic discovery, cell biology and pharmaceuticals have brought drugs, therapies, diagnostics and medical treatment. They have generated vast amounts of data. The industry needs a computational infrastructure that enables the proven business rules governing the laboratory routines and the implementation permitting faster access and error elimination.
[0003] The problem to which the invention is directed was approached on a paper-based operation previously. The situation is described below.
[0004] Case Accessioning—The following activities take place during this step.
[0005] Acceptance of a specimen
[0006] Establishment of a case file holder
[0007] Establishment of a chain of custody
[0008] Entry of basic demographic information about the case in various logs
[0009] Assignment of laboratory scientists to the case
[0010] Assignment of a case number
[0011] Laboratory Routines—This step constitutes the bulk of the case analysis and consists of both specified laboratory procedures and interpretation of laboratory results. This step can be divided into the following sub-steps:
[0012] Creation of images of case specimens
[0013] Preparing specimens for laboratory routines according to SOPs
[0014] Performing analysis and data interpretation according to SOPs
[0015] Report Writing—After obtaining the final results of laboratory routines, the laboratory scientists will make a determination, write a preliminary report, and submit the report into the review process.
[0016] Review—Designated senior laboratory scientists conduct a thorough review of the findings and, if they concur with the findings, approve the final report.
[0017] Final Report Processing—A final report is distributed to the person/agency that requested the testing. Additional copies are placed into the case folders.
[0018] Storage—The complete case file folders are stored physically.
[0019] Due to the scientific empirical nature of laboratory analysis, these paper files can be voluminous. The paper-based operation is at or near its capacity to accurately record and track cases. The FIG. 1 illustrates the paper-based operation.
[0020] Little inherent flexibility exists in the current paper-based system to accommodate increased workload or continuous refinements in the analysis process; the current system is not an efficient means of managing the laboratory routines that generates a large amount of data and provides few analysis or management tools. All documentation and reporting is paper-based, including case archives. There is no convenient method for searching previous cases for data or for generating statistical reports.
[0021] Because of the paper-intensive laboratory routines, senior laboratory scientists have few tools to track the efficiency of laboratory procedures and the scientists' practice patterns. Management oversight requires countless hours and days spent reviewing paper cases. Because of the paper media currently utilized to capture and store case data, retrieval of specific information for research or educational purposes is difficult.
[0022] Therefore, the invention suggests the SOP-driven digital network architecture of business rules and implementation to govern the laboratory routines, to eliminate clerical transcription errors, to collect data and to control the quality.
SUMMARY OF THE INVENTION
[0023] In accordance with this invention, SOP-driven Digital Network Architecture (DNA) includes at least a computer server and at least a computer client. Computer client is a software and/or hardware that ask for access. Computer server is a software and/or hardware that provide access.
[0024] The computer server has the database of the series of instructions for laboratory scientists and computer commands to perform laboratory or laboratory-related processes. The computer server is able to authenticate users and exchange the data via communication links. Upon the requests from the computer clients, the computer server will provide the series of instructions for laboratory scientists and computer commands to guide through the laboratory or laboratory-related routines. The computer server is able to store the work data of in-progress and completion resulted from the series of instructions for laboratory scientists and computer commands.
[0025] The computer client has a user interface to allow laboratory scientists to log in and to be authenticated by the computer server. The user interface enables the input of the series of instructions for the laboratory scientists and computer commands. The user interface enables laboratory scientists to select a pre-defined series of instructions and computer commands based upon the laboratory or laboratory-related routines. The user interface will guide, suggest and prompt the laboratory scientists based upon the selected series of instructions and computer commands. The user interface will post a transaction to the databases of the computer server to store the work data that are in process or complete.
[0026] Further in accordance with this invention, a method enables the creation of the security groups of laboratory scientists with discretionary security access rights to the areas of the user interface and the databases.
[0027] Still further in accordance with this invention, a method enables the scientists to create, identify and distinguish the types of pre-defined instructions and computer commands to connect to laboratory or laboratory-related routines.
[0028] Still further in accordance with this invention, a method enables the laboratory scientists to study and analyze the collections of the pre-defined instructions and computer commands via searching, sorting and reporting.
[0029] Still further in accordance with this invention, a method enables the maintenance of the database transactions of pre-defined instructions and computer commands.
[0030] Still further in accordance with this invention, a method allows the input of the pre-defined instructions and computer commands. A method allows executing the computer commands as part of a series of the instructions. A method allows connecting series of pre-defined instructions and computer commands.
[0031] Still further in accordance with this invention, a method enables connecting series of pre-defined instructions and computer commands to laboratory or laboratory-related routines.
[0032] Features and capabilities described in the specification are not all-inclusive, and particularly, many additional features and capabilities will be apparent to one of ordinary skills in the art in view of the drawings, specification, and claims hereof.
[0033] Moreover, it should be noted that the language used in the specification has been principally selected for the readability and instructional purposes, and may not have been selected to delineate or circumscribe the inventive subject matter, resort to the claims being necessary to determine such inventive subject matter.
OBJECTS AND ADVANTAGES OF THE INVENTION
[0034] The primary object of this invention is to provide a method that enables the creation and execution of the instructions for laboratory scientists to follow to perform laboratory routines.
[0035] Other objects that this invention accomplishes include:
[0036] 1. Define and refine flexibly the laboratory or laboratory-related routines
[0037] 2. Eliminate the paper-based operation
[0038] 3. Provide a means of managing the laboratory routines and data via the computer searching, sorting and reporting capability
[0039] 4. Provide electronic record management method
[0040] 5. Provide the access to the real-time management oversight
[0041] 6. Support the expert witness for the court testimony
[0042] Advantages over the previous approach:
[0043] Provide pre-defined instructions and computer commands to estimate costs, to predict results, to trace performance, to prevent mistakes, to simulate, to document innovative laboratory methods, to reconstruct laboratory routines and to develop future laboratory methods.
[0044] Use the computing capability of availability, reliability, reproducibility, repeatability, traceability, security, and the speed to execute the pre-defined instructions and computer commands
[0045] Standardize laboratory routines based on the pre-defined instructions and computer commands electronically to standardize laboratory routines
[0046] Build organizational collection of pre-defined instructions and computer commands to educate personnel, to transfer knowledge, to re-use experience and to conduct the intelligence analysis.
[0047] Further objects and advantages of this invention will become apparent from a consideration of the drawings and ensuing description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0048] [0048]FIG. 1 is an illustration of how the problem to which this invention is directed was approached previously.
[0049] [0049]FIG. 2 presents the scheme of the database system of Standard Operating
[0050] Procedure (SOP)-driven Digital Network Architecture.
[0051] [0051]FIG. 3 is a flowchart illustrating the method to define the security access rights.
[0052] [0052]FIG. 4 shows how SOP drives laboratory routines.
[0053] [0053]FIG. 5 is an organization diagram illustrating laboratory routines.
DESCRIPTION OF THE INVENTION
[0054] Method may be realized by means of a general computer server and at least one computer client in conjunction with especially designed software. Server is a computer that provides some service for other computers connected to it via network. The connection between client and server is by means of message passing over a local area network (LAN) or through Internet, and uses corresponding messaging protocol to encode and decode the client's requests and server's responses. The server should include the database used to store, manipulate and retrieve the information. Database can be implemented on a variety of commercially available database packages. A common graphic user interface is software that has to be executed at every computer client to conduct operation of the invented method.
[0055] Method comprises two types of mutually related computer-aided processes: SOP (Standard Operating Procedure) management (FIG. 2( a )) and laboratory routine (FIG. 2( b )). Here and below the Standard Operating Procedure means the set of stored in the database instructions for users and computer commands. Human instructions include text descriptions and forms placed in a predefined sequence.
[0056] Both processes physically are the retrieving, adding or modification of data in the database. They are fulfilled during the interaction of a single user from a computer client with a database running at server.
[0057] The computer server (FIG. 2( c )) contains the following general segments with structured information stored in the database:
[0058] I. Administration Segments (FIG. 2( d )):
[0059] User Information—general personal information and login that includes username and password and/or biometrics data (electronic signature), allowing authenticate user.
Definitions of User Groups:
[0060] User to Group assignment—information on user belonging to user group or groups. Access rights for User Group—security definitions of the user group's rights and privileges.
[0061] Set of SOP—each of them includes human instructions with text and forms placed in a predefined sequence and may include computer commands.
[0062] Assignments of the SOP to the types of specimen.
[0063] Assignment of individual users to the case folder.
[0064] II. Data Segments (FIG. 2( e )):
[0065] Initial data (package and/or specimen description including text, images and standard classification attributes);
[0066] Chain of custody for every specimen;
[0067] SOP assigned to the specimen or group of specimens;
[0068] Intermediate results of the specimen processing;
[0069] Final results of laboratory routines prescribed by the SOPs and filled by laboratory scientists;
[0070] Specimen Processing Related Data—such as location of storage, chemicals and equipment used to process specimen etc.;
[0071] Case folder (electronic folder joining together all case related information including the data, arbitrarily chosen by user).
[0072] The data of the Administration Segment in the FIG. 2( d ) shall be administered and input by users that are authorized to access this segment. It is illustrated by “Computer Client: authorized users (FIG. 2( f )).” The laboratory scientists that are illustrated by “Computer Client: lab scientists (FIG. 2( g ))” will input the data of the Data Segment (FIG. 2( e )).
[0073] According to claims 1 -ii and 3 invented method provides a differentiated level of security access to the data segments and means to pre-define the groups of users with discretionary access rights. The underlying mechanism is shown on FIG. 3, numbers on a diagram correspond to those that enumerate the database segments on FIG. 2.
[0074] Mechanism uses security features of the database software that allow database administrators to manage user's access to every database table and their rights to modify data in that table. Additionally to the user identification and his or her roles defined at the level of the database, this mechanism uses the security level of a user interface of the computer client and that is called client application.
[0075] After logging in and successful authentication of a user (FIG. 3( a )), client application inquiries the database to find out what groups and cases current user is assigned to. This will determine the group access rights (FIG. 3( b )) to allow access in the Graphical User Interface (GUI) at client computer. Respectively, the restricted informational segments will not appear on a GUI and read-only areas will allow only view the non-editable information. Analogously, the determining of a case access (FIG. 3( c )) gives a list of case folders available for a given user. Thus, the appearance of the GUI at client computer varies in dependence on access rights of a user group or groups.
[0076] Main features of the described mechanism of the differentiation in access rights: Rights of user groups are defined in terms of data segments—at more global and structured level than establishment of user or user group rights for every table at database server;
[0077] Access rights management is a part of GUI at computer client, available for the members of such groups as laboratory supervisors/managers who may not necessarily have special skills for database administration. They may allow or restrict the access to the data segments without knowing of table names or data structure.
[0078] Rights of user access may vary within the limits of one database table. As system is designed to provide individually dependent data for every user, the available information on laboratory routines and their results are selected basing on the “Determining of Case Access” (FIG. 3( c ) resulting from the “Assignment of individual Users to the Case Folders” (FIG. 2( 7 )). GUI is being built individually at client computer in accordance with access rights of group or groups that current user is assigned to.
[0079] As it was stated in the beginning of the description of the invention, two mutually related computer processes: SOP management and laboratory routine constitute the entity of the invented method. Both processes start from the steps of getting the access rights for the logged user according to described mechanism. These steps are as follows:
[0080] Server authentication of user;
[0081] Determining of security group or groups that current user is assigned to;
[0082] Obtaining the level of security access (Write, Read Only or None) of the logged user for every enumerated below process or process part that are reflected as data segments in the database and GUI.
[0083] Further parts of the SOP management process, that may not necessarily be subsequent, are:
[0084] Defining and refining the SOP contents;
[0085] Version control: creating a new SOP and a new version of the existing SOP;
[0086] retirement of the obsolete SOPs.
[0087] Assignment of SOP or SOP set to the types of specimens.
[0088] Further parts of the laboratory routine process, that have to be subsequent, are:
[0089] Entering the initial specimen information including first member of the custody chain;
[0090] Assignment of SOP to the specimen or group of specimens;
[0091] Entering the intermediate results according to the assigned SOP and specimen transfer to the next member of the custody chain;
[0092] The number of times of repeating process—entering the intermediate results and specimen transfer to the next member of custody chain—depends on the assigned SOP. That forms the chain of custody and contents of the case folder;
[0093] Typing the final result, approval and closing the case folder.
[0094] The object model of the system implementing the invented method is illustrated on FIG. 4. It shows in detail the SOP management process (1) and its interaction with the laboratory routine processes (2).
[0095] “SOP defining” module (FIG. 4( a )) suggests the determination of the SOP content: type of SOP, forms that need to be filled sequentially to complete the SOP, text with the additional instructions for users or comments. Computer commands could be written as part of SOP if the created procedure should have features like gathering data (files) from instrumental interface of any device attached to the computer client. Sequence is an essential part of the SOP. It defines the order in which the SOP data will appear at the GUI of a computer client and this order is required in the fulfillment of the prescribed operations.
[0096] “Version control” module (FIG. 4( b )) includes creating the new version of the existing SOP and retirement of the obsolete SOP. Version control expands on the entire system preventing from using different versions of the same SOP. Particularly, only one version of the SOP can be active and may be in use.
[0097] “The SOP assignment to specimen types” (FIG. 4 ( c )) establish relations between the predefined types of the specimens and SOP.
[0098] The laboratory routine itself starts from “assignment of SOP to the specimen or group of specimens” (FIG. 4( d )). At this stage the SOP is chosen from the list of SOPs available for that type of specimen. It is intended to provide technical and organizational instructions on the processing of specimen and includes the descriptions of all operations of the specimen analysis. Forms may be included if necessary to document the process and as a container to put the intermediate and final results in. If the computer commands are included to the SOP, they are being executed at the predefined step of the SOP fulfillment requiring data input from user or gathering data from the instrumental interface.
[0099] The final aim of the described object model is shown as a rectangle (e) in FIG. 4—that are the SOP-prescribed user actions and computer commands, specific for every type of specimen. Instructions and forms that have to be filled determine user actions.
[0100] The scheme of laboratory routine workflow is illustrated in FIG. 5. The process starts from the logging of the specimen or specimens to the system and assignment of user and SOP to each of them (SOP assignment corresponds to FIG. 4( d )). The first informational block—“Package” is optional and serves as a tool to combine and store the information about specimen's origination: sender name and address, identification numbers, name of delivery service, image and etc. Following to the assigned SOP, actions are executed under the specimen and intermediate results, having the form of text, image and/or filled prescribed form, are stored in the database. Further, the next personal assignment follows and next step of the SOP is fulfilled resulting in the record of the next intermediate result in the database. This procedure is repeated the number of times dependent on assigned SOP until the SOP is complete. All the information regarding particular specimen form the chain of custody of that specimen. The chain of custody along with intermediate and final results, assigned SOP and information on specimen origination build the case folder content. Finally the case folder is the subject of approval, closing and archiving.
Advantages
[0101] From the description above, a number of advantages of the invention become evident:
[0102] The availability of electronic SOPs using computer networks enables the access to the organizational standard without the geographical limitation. Different scientists at different places can access the standard SOPs.
[0103] The scalability of electronic SOP management using computer networks enables the efficient, accurate and synchronized version control and approval processes. Managing SOPs becomes possible to update, deactivate, activate at different scale and at scheduled timelines within the organization computer networks.
[0104] The reliability of electronic SOP management using computer networks enables replication of SOPs and the related data to recover from disaster. As opposed to relying on paper storage, the electronic SOPs and related data can be duplicated in different media formats to assure the permanent archival and future transformation. The repeatability of the electronic SOPs and the data gathered via executing SOPs using computer networks enables the capability of dataflow tracing. The computational infrastructure of the management of electronic SOPs, the execution of SOPs, the association between SOPs and the data that result from the execution of the SOPs creates an automated computer environment that monitors, guides and standardizes the business operation. Conclusion, Ramifications and Scope of Invention
[0105] Accordingly, the reader will see that the SOP-driven digital network architecture of this invention is a computational environment that:
[0106] 1. Assist in the compliance with the Good Laboratory Practice (GLP)
[0107] 2. Manage the laboratory routines using a set of standard procedures
[0108] 3. Simulate laboratory routines
[0109] 4. Estimate the cost of laboratory routines
[0110] 5. Manage the laboratory risk
[0111] 6. Troubleshoot errors
[0112] 7. Train the laboratory scientists
[0113] 8. Maintain the historical data
[0114] 9. Build statistics
[0115] 10. Re-construct the laboratory routines
[0116] 11. Re-produce the errors
[0117] 12. Quality assure the laboratory performance
[0118] 13. Document the innovative intellectual processes
[0119] While the above description contains many specifications, these should not be construed as limitations on the scope of invention, but rather as an exemplification of one preferred embodiment thereof. Many computer networks comprising computer servers, computer clients and GUIs can be designed to use the method of the invention. For example, the computer server can use different operating systems with various computer clients; using different computer programming languages can develop computer client user interface.
[0120] Accordingly, the scope of the invention should be determined not by the description of the invention, but by the claims and their equivalents. | Standard Operating Procedure (SOP)-driven Digital Network Architecture monitors, tracks laboratory routines and creates electronic records. The invention enables laboratory scientists to design, manage, control, and reproduce laboratory routines. The invention creates electronic system to identify where, who and when the quality deteriorates in laboratories. SOPs mean instructions of which texts for scientists and directives for computers. Methods include two mutual computer-aided processes—SOP management and laboratory routine. Both processes start with user authentication, security group, security access to SOPs and laboratory routine. Further SOP management that may not be subsequent is defining and refining contents of SOPs; version control, retirement and assignment of SOP to specimens. Further laboratory routine that must be subsequent include assigning SOPs to checked-in specimen, chain of custody; test results based upon SOPs; repeating the steps according to SOPs and forming chain of custody, test results; case approval and closing the case. | 6 |
BACKGROUND
The present invention relates to multi-channel retailing competition and, more particularly, to a simulation system and methodology to assist retail entities to make multi-channel business decisions dynamically.
Larger retail companies use multiple channels to sell their merchandise. Multiple channels include physical stores, web sites, catalogs, etc. The industry continues to invest heavily to sustain and renew these channels (e.g., global e-retail market size reached $80B in 2006). But multi-channel retailers are facing the challenges of how to make right strategies (price, service, etc.) to adopt the competing and dynamic multi-channel environment. Multi-channel retailing competition is very complex as:
1) There is complex relationship among channels, the channel conflict and channel coordination both should be both considered. 2) The market is dynamic. 3) There are multiple players: retailers from different competitors and customers in different segments.
To make informed decisions, it is necessary for retailers to be able to identify channel influences and customer preferences according to sales and price history of different channels/retailers.
SUMMARY
In one aspect there is provided a system, method and computer program product that provides the ability for retailers to devise a current channel strategy (e.g., adaptive price setting) that considers competitors in a dynamic competing environment, and that enables computing a competitive advantage of a channel.
According to one aspect, there is provided a system, method and computer program product to estimate a price for selling a product j in a commerce channel comprising: a) receiving, at a processor device, real market data including sales and price history data of a product j sold by one or more retailers over one or alternate sales channels t; b) generating, by the processor device, a competitive advantage parameter value based on the sales and price history data; and, c) computing, utilizing the competitive advantage parameter value, an optimum price for a particular product to be marketed in one of the one or alternate sales channel.
Further to this aspect, the generating, by the processor device, of a competitive advantage parameter value comprises: receiving at input nodes of configured neural network, a data vector including the prices and customer preferences of a product j at different times, the configured neural network representing a dynamic procedure of competition in retailer market; propagating the data to one or more intermediate nodes of the configured neural network; and, implementing a function, at the intermediate nodes, for calculating a customer preference parameter value C ij t .
In a further aspect, the method includes implementing a back propagation computation of said neural network to obtain gradients for use in calculating said customer preference parameter value C ij t .
Furthermore, the method comprises: calculating a competitive advantage ψ ij k of customer segment i and product j in channel t according to:
ω ij t ( k )=max{θ 1 max{0 ,p j s −p j t },θ 2 max{0 ,C ij t −C ij s }}
where k denotes a time period, p j s (p j t ) denotes the price of product “j” in respective channel s(t), c ij t (c ij s ) denotes a calculated customer preference parameter value for respective channel t(s) of customer segment “i” while buying product “j”, and theta “θ” represents a relationship between two products. For example, θ 1 , θ 2 are the weights of price and customer preference, respectively, e.g., for the same θ 2 , θ 1 being large indicates customer valuing price more. θ 1 and θ 2 are identified from real marketing data, hence not only their ratio, but their values are meaningful.
In one embodiment, the method further comprises: producing, at output nodes of said neural network, a simulated sales volume q ij t based on said competitive advantage parameter value ψ ij k , wherein said sales volume is computed for a channel t in a particular price setting.
Further to this embodiment, the simulated sales volume q ij t is computed at output nodes of the configured neural network according to:
q ij t ( k )=[adjustment factor]ψ im t
where ψ im t is the competitive advantage parameter value.
BRIEF DESCRIPTION OF THE DRAWINGS
The objects, features and advantages of the present invention will become apparent to one skilled in the art, in view of the following detailed description taken in combination with the attached drawings, in which:
FIG. 1 depicts an overview of one embodiment of the Dynamic Competition Model used for Multi-Channel Retailing among Multiple Retailers according to one embodiment;
FIG. 2 depicts one example rule of the rules in computing the competitive advantage of a channel according to one embodiment;
FIG. 3 shows one formula for computing sales volume of a product from a channel according to one embodiment;
FIG. 4 shows the backward Judge Neural Network that may be implemented for obtaining gradients for computations used according to one embodiment;
FIG. 5 is a flow chart depicting the method implemented in competing simulation block 30 to enable a retailer to optimize their competitive advantage; and,
FIG. 6 illustrates an exemplary hardware configuration performing methods of the Dynamic Competition Model in one embodiment.
DETAILED DESCRIPTION
FIG. 1 depicts an overview of the Dynamic Competition Model 10 according to one embodiment. The Dynamic Competition Model includes three computation modules: Data Integration 11, Parameter Identification 20 , and Competition Process Simulation 30 .
1) Data Integration module 11 initializes the Dynamic Competition Model by obtaining (e.g., receiving) and integrating initialization data from multiple sources into a unique platform (such as shown in FIG. 1 ). These input data include channels information and sales and price history data (e.g., sales series of different retailers, and price series of different retailers). For instance, the input data may include whether or not a retailer sells particular product, the prices of different products in different retailers for a pre-determined amount of time (e.g., 1000 days), the sales quantities of corresponding products in different retailers at different days, etc.
2) Parameter Identification module 20 using a Judge Neural Network 100 : Apart from the initialization data, there exist key parameters in the Dynamic Competition Model that are first identified. A Judge Neural Network 100 is configured to determine the key parameters in the Dynamic Competition Model. With sales and price history data as the input, the JNN determines key parameters including but not limited to: channel influence and customer preference parameters. Two parameters include θ 1 , θ 2 which are independent but will be identified together. The “competitive advantage” variable will affect the estimated sales quantity through the propagation along the neural network. That is, in one embodiment, the parameters in the JNN are identified using real market data. A Newton Descend method commonly used to train unknown parameters may be used, in one embodiment, to reduce the value of the cost function. Alternative to Newton Descend method, the unknown parameters can be trained using, for example, Gradient Descent method, Quasi-Newton method or Generation Algorithm (see Nocedal, Jorge and Wright, Stephen J. (1999) Numerical Optimization, Springer-Verlag, contents and disclosure of which is incorporated by reference). As will be described in detail herein below, the JNN uses the gradients (e.g., the change rates of sales quantity to factors) calculated from the backward neural network of the JNN, e.g., as shown in FIG. 4 . In this manner, key parameters are obtained, such as customer preference, which parameter information could have only been retrieved from prior art surveys.
3) Competition Process Simulation 30 : After computing these key parameters via the JNN, the configured JNN 100 is used to perform a simulation and produce a final solution such as: an optimization of the price of channels in competition, or, the observing of resulting effects of different price setting and channel coordination strategies.
In one embodiment, the Judge Neural Network is a type of Neural Network and, as shown in the example Node A of the JNN portion 120 shown in FIG. 2 , the JNN includes three layers: an input layer, at least one hidden layer, and an output layer. It differs from artificial neural network (ANN) configurations in how the data from the previous layer propagates to the next layer. However, in the identification procedure, JNN is like a special ANN, where the data propagating to the next layer will keep the same in some range due to the piecewise linear property of JNN. This configuration can save computing load in the backward propagation step.
FIG. 2 illustrates an example portion of a Judge Neural Network 120 including interconnected nodes, e.g., Nodes A-C of the network in the embodiment shown, is a middle layer(s) node connected by “m” in-nodes from a previous layer (not shown), and it connects to “n” out-nodes of a next layer (not shown). In FIG. 2 , the Node A of the JNN portion 120 includes elements that denote the relationship between the output and the input(s) of Node A. In one embodiment, the input nodes of JNN include a data vector including the prices and customer preferences of a product in question. The output nodes are the sales volumes. Other variables are represented by middle/hidden nodes. In the embodiment of node A shown in FIG. 2 , and, in the embodiment of the backward propagation network shown in FIG. 4 , node A “sub” element 201 denotes that the relationship between the outputs and the inputs of the node is a subtraction, i.e., the output of the node equals the difference between two input values. The elements “min” 203 denotes an operation producing an output that is a minimum of the inputs at the node; element “log” 207 denotes an operation producing an output that is a logarithm of the inputs of the node; that the relationship between the outputs and the inputs of the node is a logarithm; element “max” 205 denotes an operation producing an output that is a maximum of the inputs at the node; and, element “sum” 209 denotes an operation producing an output that is a summation of the inputs of the node input values.
Several functions are defined using the “m” in-nodes as the input to compute the output of this node. Based on proper assumptions (i.e., the assumption should be reasonable and accepted by all customers), these functions include:
max{max{p j s −p j t ,0},max{ c ij t −v ij s }}
such as shown in FIG. 2 , in which term p j s (p j t ) denotes the price of product “j” in channel s(t), and term c ij t (c ij s ) denotes the customer preference for channel t(s) of customer segment “i” while buying product “j”. For example, this function comes from the assumption that if the price in the s th channel is higher and customers like the t th channel more, they will not buy product j from s th channel, i.e., the sales quantity should be zero. The function determines the competitive advantage of a channel, e.g., channel “t” over channel “s” based on an assumption that, while buying product “j”, if the customer likes channel “s” more than channel “t” and channel “s” offers a price lower than channel “t”, then the customer will buy it from channel “s”. Thus, for example, if p j t >p j s and c ij s <c ij t , then customer i will not buy product j from channel t. As mentioned, the elements of each node in middle layer(s) such as Node A of FIG. 2 informs what computation to perform when the inputs are identified. For example, use of “sub” element 201 subtracts input 2 from input 1 , and “max” element 205 chooses the maximum value of all the inputs. In the embodiment shown in FIG. 2 , the function related with Node A is
ψ ij t ( k )=max{θ 1 max{0 ,p j s −p j t },θ 2 max{0 ,C ij t −C ij s }}
After the prices and customer preferences are set in the input layer, the output 225 of a first middle layer such as shown in Node A is obtained according to the functions defined in the network, which then serve as the input to a further (e.g., a second) middle layer (not shown), and the propagation continues until the output layer is determined. For example, a situation exists that the value of output layer can be known without considering some other value. For example, in the forward propagation (see FIG. 4 ), the output of 203 will be zero if one input of 203 is zero. This is an advantage of JNN, which can save computing time.
In certain portions of the middle layers, a key variable, ψ ij t (k) 225 , where k represents a different time (i.e., different set of training data), is used to represent a calculation of a competitive advantage of customer segment i and product j in channel t, which helps in the computation of variable q ij t 250 , a variable representing sales volume of product j in channel t from customer segment i. For example, the ψ ij t (k) variable 225 is the bridge of variable 250 and the variables observed like prices. Especially, in identification, the “help” is prominent since the derivatives are computed from backward neural networks where variable 225 is a key middle node as FIG. 2 shows. The larger the variable 225 is, the more sales volume will be, but the relationship is not a simple linear one. Moreover, the interplay between calculation of ψ ij t (k) and calculation of variable q ij t also appears in parameters identification, where the sampling data of sales volume is used to train the parameters of variable 225 .
In one embodiment, JNN portion 120 shown in FIG. 2 calculates variable ψ ij t (k) 225 representing the competitive advantage of customer segment i and product j in channel t. Given four inputs (in the embodiment shown), this value is computed from the network as FIG. 2 depicts. For example, when the conditions in FIG. 2 are satisfied, e.g., if p j t >p j s and c ij s <c ij t , then competitive advantage variable ψ ij k computes to zero, and customer i will not buy product j in channel t. This variable may affect the sales volumes; for example, when it equals zero, the sales volume is zero.
In one embodiment, shown in FIG. 2 , a supervised learning approach can be used to configure the JNN. For example, a JNN learning algorithm 101 is employed that receives as inputs 102 a series of market data, including the prices and sales volumes at different times. Using initial parameters, described in greater detail below, at 103 the JNN produces data such as a simulated sales volume q ij t . The difference, i.e., error, between the simulated sales volume compared with real sales volumes is calculated at 105 . Based on the error feedback 108 to the JNN network, there is computed an adjustment for the parameters, with the gradient calculated by the backward network of JNN, and the JNN produces a new sales volume using the adjusted parameters. This supervised learning process is iterated, i.e., is an iterative procedure and the “best” parameters of JNN are determined from the iteration(s) that occur when the estimation error is “least”; the estimation error, for example, being the sum of squared residuals between sampling sales volume and the sales volume calculated by the JNN.
After computing these parameters, the configured JNN is used to perform a final simulation and produce a final solution, such as described herein below with respect to FIG. 4 .
As mentioned, in one embodiment, for the supervised training approach used to train the Judge Neural Network 100 , there are four types of input parameters: product price, product cost (cost of manufacturing product or the cost retailers pay), customer preference, and customer population. During each iteration, the sales volume computed by JNN is compared with the real data, and the error is calculated, then the parameters are adjusted, e.g., using Newton method. The gradients are computed from the backward network of JNN 122 of FIG. 4 as part of a known propagation process. In JNN, the grads are used not only to identify the parameters, but also used for competition simulation. That is, in the dynamic simulation of JNN, each retailer will allodially (independently) change its price according to these grads. The iteration proceeds to identify optimum parameters until a mean square error value
θ * = min θ 1 K ∑ t = 1 K ( q obs ( k ) - q model ( θ , ( p ) ) ) 2
(e.g., error being the differences between the real sales quantity and the sales quantity computed by JNN) is lower than a pre-set limit. In one embodiment, optimal parameters are the ones getting least error.
FIG. 3 depicts a formula 300 by which a processor or computer device computes output representing a sales volume of product j in channel “t” from customer segment i using competitive advantage variable ψ ij k . That is,
q ij t ( k ) = ∑ m = 1 M { θ mj ⅇ β 0 + β 1 ( cost m 1 - p m t ( k ) ) 1 + ⅇ β 0 + β 1 ( cost m 1 - p m t ( k ) ) ψ im t ( k )
where θ mj is the product relationship between two products, e.g., products j and m (for example, if someone purchases a TV set, it is possible that he/she will buy a DVD player. Then the θ mj parameter between TV set and DVD player would be a large positive value, for example;
ⅇ β 0 + β 1 ( cost m 1 - p m t ( k ) ) 1 + ⅇ β 0 + β 1 ( cost m 1 - p m t ( k ) )
is a computed adjustment factor, t is the channel, and k is time (training data). To obtain the value of q ij t (k), the parameters β 0 , β 1 , and θ mj are first identified in JNN with β 0 , β 1 being two factors that affect the shape of a logistic function which is used widely for prediction. It is understood that the logistic function is a very common function and widely used to describe things having upper and lower bounds and is applied to the JNN; however, any other reasonable functions, which are monotone and have upper and lower bounds, are suitable. Cos t m and price p m (as explained herein above) and competitive advantage variable ψ ij t (k) are the input variables of FIG. 3 , with the price, cost and ψ ij t (k) obtained from the JNN node processing of FIG. 2 . Thus, from the Judge Neural Network 100 , the simulated sales volume q ij t can be computed in every channel in a particular price setting. In one embodiment, not only does the price affect customer's purchase intention, the sales volume also does.
Thus, in one aspect, the JNN 100 assists in making multi-channel decision(s) dynamically for an entity, e.g., retailer, company or other business organization, by enabling one to identify channel influence and customer preference according to sales and price history of different channels/retailers; and, to give channel strategy (e.g. adaptive price setting) that considers competitors in a dynamic competing environment. That is, JNN describes a dynamic procedure of competition in a retailer market, i.e., when using JNN to make multi-channel decision(s), JNN will consider the change and reaction of all channels—and not just treat them in static state.
Competition Process Simulation
As described above at 30 , FIG. 1 , the system uses the configured JNN 100 to perform a simulation and produce a final solution such as: an optimization of the price for the products which will be marketed in channels in competition 301 , or, the observing of resulting effects of different product price setting and channel coordination strategies 305 . The dynamic price setting model 30 to simulate the real multi-channel dynamic competing environment is now described with respect to FIG. 1 . In this aspect, at 303 , FIG. 1 , data, including data for N channels, M products and L customer segments are provided as input 310 to the JNN 100 used in this simulation.
In this embodiment, Equation 1) provides an example objective function of a t th channel represented as G t (p j t ,q ij t ) which incorporates sales volumes, profit, market share, etc., represented as:
G
t
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j
t
,
q
ij
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=
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j
t
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j
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ij
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=
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That is, there is obtained an objective function G t for each channel t, where equation 1) is a special case where the objective function is set to be profit that can be computed by multiplying the sales quantity with the difference between price and cost of product t.
In a further aspect, as shown in FIG. 1 , the present invention utilizes the configured JNN 100 to optimize the price of products to be marketed in channels in competition at 305 . That is, in an example implementation, a company changes prices in order to obtain the maximum profit and, in addition, to maintain a sales advantage over other competitors. In changing the price to an optimum value for the products which will be market in, the optimized price can be given, the company takes into consideration how other companies (e.g., competitors) change their prices. Equation 2) represents a price iteration formula based on the analysis above as:
p j t ( k + 1 ) = p j t ( k ) + λ t ∂ G j t ∂ p j t ( k - t lag ) - ∑ r ∈ competitor ξ tr ∂ G j r ∂ p j t ( k - t lag ) ( 2 )
Where k is a time point, t lag denotes the time lag for competition (i.e., as a retailer typically cannot get real-time information to make decision and can only change the price based on some prior information) and is a nonnegative integer, if and only if “t” is an e-channel t lag =0 where e-channel represent an internet commerce (where a retailer “r” sell products on-line). Since via the internet, the retailer r will get more real-time information, its time lag is set to zero, showing this advantage of e-channel to traditional ones; and, λ t and δ tr are parameters describing different behaviors of different retailers. For example, if the retailer will change the price tempestuously, λ t would set to be a large value. λ t and δ tr are the parameters describing the behaviors of retailers. Like λ t , if the retailer will change the price tempestuously, δ tr , would set to be a large value. The difference between λ t and δ tr is that λ t is trying to increase own sales volume while δ tr considers to decrease the sales volume of competitors.
In a further aspect, the method further determines how two channels cooperate when they belong to the same company. Normally, when the sales from one channel increases or drops, sales from the other channels is likely to fluctuate in the same way. Accordingly, the formula of equation 2) is revised to equation 3) as follows:
p j t ( k + 1 ) = p j t ( k ) + λ t ∂ G j t ∂ p j t ( k - t tag ) + λ t ∂ G j s ∂ p j t ( k - t tag ) - ∑ r ∈ competitor ξ tr ∂ G j r ∂ p j t ( k - t tag ) ( 3 )
Thus, in the competition simulation, time is updated from k=1, and the price in the next time k+1 is computed according to equation (3), where the parameters λ t , t tag , and δ tr are set in advance and other variables, e.g., θ 1 , θ 2 ( FIG. 3 ), β 0 , β 1 (in FIG. 4 ) determined using the described method, are computed in the simulation. As mentioned above, λ t and δ tr are parameters describing the strategy of a retailer.
∂ G j r ∂ p j t
is the grads computed by the backward propagation of JNN. The last summation term represents the endeavor for decreasing the profit of the competitors.
In one embodiment, both G and
∂ G ∂ p
can be obtained from JNN. After a pre-defined K iteration steps, a price is computed that best fits in the business competition. That is, by using the backward propagation of the JNN, the
∂ G ∂ p
can be computed and, then, according to (3), the price at every time point in a dynamic simulation can be obtained.
FIG. 5 depicts a method implemented in competing simulation block 30 to enable a retailer to optimize their competitive advantage when marketing in different price scenarios, under different channels and with/without competitors. As seen in FIG. 5 , the procedure 300 is provided for a retailer to optimize his/her strategy. For this he/she first collects information at 302 including: a series of prices and sales quantities (e.g., data for a channel, product and a customer segment) and strategies of any competitors, and then, implements the method provided herein to identify the parameters of JNN. For example, at 304 , the retailer's historical sales data may be used to train the parameters in order to minimize the residuals between real sales quantity and the JNN output. Then, at 308 , he/she chooses one strategy and at 311 , uses the JNN to simulate the performance of the chosen strategy. For example, the retailer may 1 ) choose a strategy to sell or not sell a particular product in a particular retail channel in competition; 2) choose a strategy to fix a price of a particular product in a particular retail channel in competition; 3) choose a strategy for changing a price of a particular product in a particular retail channel in competition; or 4) choose a strategy for improving the competitive advantage. Then, at 314 a determination is made as to whether the simulated performance of the strategy is satisfied. If the performance is satisfied, the strategy can be put in to use at 318 . Otherwise, he/she can adjust the strategy by returning to step 308 , and test/simulate the new strategy in JNN. It is noted that in simulation, one can also adjust the competitive advantage to see if it is changed how the performance will be improved.
FIG. 6 illustrates an exemplary hardware configuration of a computing system 400 running and/or implementing the method steps described herein. The hardware configuration preferably has at least one processor or central processing unit (CPU) 411 . The CPUs 411 are interconnected via a system bus 412 to a random access memory (RAM) 414 , read-only memory (ROM) 416 , input/output (I/O) adapter 418 (for connecting peripheral devices such as disk units 421 and tape drives 440 to the bus 412 ), user interface adapter 422 (for connecting a keyboard 424 , mouse 426 , speaker 428 , microphone 432 , and/or other user interface device to the bus 412 ), a communication adapter 434 for connecting the system 400 to a data processing network, the Internet, an Intranet, a local area network (LAN), etc., and a display adapter 436 for connecting the bus 412 to a display device 438 and/or printer 439 (e.g., a digital printer of the like).
As will be appreciated by one skilled in the art, aspects of the present invention may be embodied as a system, method or computer program product. Accordingly, aspects of the present invention may take the form of an entirely hardware embodiment, an entirely software embodiment (including firmware, resident software, micro-code, etc.) or an embodiment combining software and hardware aspects that may all generally be referred to herein as a “circuit,” “module” or “system.” Furthermore, aspects of the present invention may take the form of a computer program product embodied in one or more computer readable medium(s) having computer readable program code embodied thereon.
Any combination of one or more computer readable medium(s) may be utilized. The computer readable medium may be a computer readable signal medium or a computer readable storage medium. A computer readable storage medium may be, for example, but not limited to, an electronic, magnetic, optical, electromagnetic, infrared, or semiconductor system, apparatus, or device, or any suitable combination of the foregoing. More specific examples (a non-exhaustive list) of the computer readable storage medium would include the following: an electrical connection having one or more wires, a portable computer diskette, a hard disk, a random access memory (RAM), a read-only memory (ROM), an erasable programmable read-only memory (EPROM or Flash memory), an optical fiber, a portable compact disc read-only memory (CD-ROM), an optical storage device, a magnetic storage device, or any suitable combination of the foregoing. In the context of this document, a computer readable storage medium may be any tangible medium that can contain, or store a program for use by or in connection with a system, apparatus, or device running an instruction.
A computer readable signal medium may include a propagated data signal with computer readable program code embodied therein, for example, in baseband or as part of a carrier wave. Such a propagated signal may take any of a variety of forms, including, but not limited to, electro-magnetic, optical, or any suitable combination thereof. A computer readable signal medium may be any computer readable medium that is not a computer readable storage medium and that can communicate, propagate, or transport a program for use by or in connection with a system, apparatus, or device running an instruction. Program code embodied on a computer readable medium may be transmitted using any appropriate medium, including but not limited to wireless, wireline, optical fiber cable, RF, etc. or any suitable combination of the foregoing.
Computer program code for carrying out operations for aspects of the present invention may be written in any combination of one or more programming languages, including an object oriented programming language such as Java, Smalltalk, C++ or the like and conventional procedural programming languages, such as the “C” programming language or similar programming languages. The program code may run entirely on the user's computer, partly on the user's computer, as a stand-alone software package, partly on the user's computer and partly on a remote computer or entirely on the remote computer or server. In the latter scenario, the remote computer may be connected to the user's computer through any type of network, including a local area network (LAN) or a wide area network (WAN), or the connection may be made to an external computer (for example, through the Internet using an Internet Service Provider).
Aspects of the present invention are described below with reference to flowchart illustrations (e.g., FIG. 1 ) and/or block diagrams of methods, apparatus (systems) and computer program products according to embodiments of the invention. It will be understood that each block of the flowchart illustrations and/or block diagrams, and combinations of blocks in the flowchart illustrations and/or block diagrams, can be implemented by computer program instructions. These computer program instructions may be provided to a processor of a general purpose computer, special purpose computer, or other programmable data processing apparatus to produce a machine, such that the instructions, which run via the processor of the computer or other programmable data processing apparatus, create means for implementing the functions/acts specified in the flowchart and/or block diagram block or blocks. These computer program instructions may also be stored in a computer readable medium that can direct a computer, other programmable data processing apparatus, or other devices to function in a particular manner, such that the instructions stored in the computer readable medium produce an article of manufacture including instructions which implement the function/act specified in the flowchart and/or block diagram block or blocks.
The computer program instructions may also be loaded onto a computer, other programmable data processing apparatus, or other devices to cause a series of operational steps to be performed on the computer, other programmable apparatus or other devices to produce a computer implemented process such that the instructions which run on the computer or other programmable apparatus provide processes for implementing the functions/acts specified in the flowchart and/or block diagram block or blocks.
The flowchart and block diagrams in the Figures illustrate the architecture, functionality, and operation of possible implementations of systems, methods and computer program products according to various embodiments of the present invention. In this regard, each block in the flowchart or block diagrams may represent a module, segment, or portion of code, which comprises one or more operable instructions for implementing the specified logical function(s). It should also be noted that, in some alternative implementations, the functions noted in the block may occur out of the order noted in the figures. For example, two blocks shown in succession may, in fact, be run substantially concurrently, or the blocks may sometimes be run in the reverse order, depending upon the functionality involved. It will also be noted that each block of the block diagrams and/or flowchart illustration, and combinations of blocks in the block diagrams and/or flowchart illustration, can be implemented by special purpose hardware-based systems that perform the specified functions or acts, or combinations of special purpose hardware and computer instructions.
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 scope of the invention not be limited to the exact forms described and illustrated, but should be construed to cover all modifications that may fall within the scope of the appended claims. | A system, method and computer program product for providing the ability for retailers to devise a current channel strategy (e.g., adaptive price setting) that considers competitors in a dynamic competing environment, and that enables computing a competitive advantage of a channel. To estimate a price for selling a product j in a commerce channel comprises: a) receiving, at a processor device, real market data including sales and price history data of a product j sold by one or more retailers over one or alternate sales channels t; generating, by the processor device, a competitive advantage parameter value based on the sales and price history data; and, computing, utilizing the competitive advantage parameter value, an optimum price for a particular product to be marketed in one of the one or alternate sales channel. | 6 |
BACKGROUND OF THE INVENTION
The present invention relates generally to a process for producing organic halide compounds, and more in particular to a process for producing substituted benzotrihalide compounds.
Substituted benzotrihalide compounds are a known class of compounds used in various commercial applications. One of the most valuable applications is as an intermediate in making herbicides such as, for example, trifluralin, benefin, fluchlovalin, dinitramine, profluralin, ethyl fluralin, chloramber, 2,3,6-trichlorobenzoic acid, and the like.
Various methods have been employed to produce substituted benzotrihalides. In one method, 4-chlorobenzotrichloride was produced by a multi-step reaction starting with toluene. In this reaction, toluene was chlorinated in the presence of iron chloride at a temperature of from about 90° to about 100° C. to form an isomeric mixture of ortho- and para- chlorotoluene which was resolved by distillation. The para-isomer was then reacted with gaseous chlorine in the presence of ultraviolet light to chlorinate the side chain carbon of the chlorotoluene molecule. The resulting 4-chlorobenzotrichloride has been converted to 4-chlorobenzotrifluoride by methods such as that taught in U.S. Pat. No. 4,045,502.
In another method for producing 4-chlorobenzotrichloride, toluene was sulfonated with chlorosulfonic acid to form a mixture of the ortho- and para- isomers of toluenesulphonyl chloride. This isomeric mixture was resolved on the basis of melting points. The para-isomer was then converted to 4-chlorobenzotrichloride by allowing it to react with chlorine in an inert medium under irradiation with ultraviolet light as described in U.S. Pat. No. 3,230,268 and by B. Miller, and C. Walling in J. Am. Chem. Soc., 79, 4187 (1957).
Nearly all the present industrial processes for producing the substituted benzotrihalides, especially the monosubstituted benzotrihalides, suffer from the disadvantage of producing a mixture of position isomers which must be resolved.
A need, therefore, exists for a process which produces good yields of the desired product while selectively controlling the production of position isomers, especially the ortho- and para-isomers of the monosubstituted compounds.
SUMMARY OF THE INVENTION
The present invention is a process for the production of substituted benzotrihalide compounds comprising pyrolyzing a substituted phenyl trihaloacetate of the formula: ##STR2## wherein each X is halo, nitro, alkyloxy, aryloxy, aralkyloxy, cyano, lower alkyl, haloalkyl, haloalkyloxy, alkenyl, haloalkenyl, carbamoyl, N,N-dialkylcarbamoyl, N,N-diarylcarbamoyl, or N,N-diaralkyloxy;
Y is halo; and
n is an integer of from 1 to 5; to form a substituted benzotrihalide of the formula: ##STR3## wherein X, Y, and n are as defined above.
The desired products are formed in high yields and purity.
DETAILED DESCRIPTION OF THE INVENTION
Substituted phenyl trihaloacetates of formula I are thermally converted to the corresponding substituted benzotrihalide compounds of formula II by pyrolysis. Pyrolysis is defined as the transformation of a compound into one or more other substances by heat alone. Preferably the pyrolysis takes place in the presence of an inert contact medium or catalyst. The reaction involves the cleavage of an aromatic carbon-oxygen bond with the elimination of carbon dioxide as illustrated by the equation: ##STR4## wherein X, Y, and n are defined above.
Illustrative examples of substituted phenyl trihaloacetates suitable as starting material in the process include the following:
4-bromophenyl trichloroacetate
4-n-butoxyphenyl trichloroacetate
2-chloro-4,5-dimethylphenyl trichloroacetate
2-chloro-5-methylphenyl trichloroacetate
2-chloro-4-nitrophenyl trichloroacetate
4-methylphenyl trichloroacetate
2-cyanophenyl trichloroacetate
2,4-dichlorophenyl trichloroacetate
2,6-diisopropylphenyl trichloroacetate
2,3-dimethoxyphenyl trichloroacetate
2,3-dimethylphenyl trichloroacetate
2,4-dinitrophenyl trichloroacetate
4-dimethylcarbamoyl phenyl trichloroacetate
4-carbamoylphenyl trichloroacetate
4-diphenyl carbamoylphenyl trichloroacetate
4-dibenzylcarbamoylphenyl trichloroacetate
3-methyl-4-nitrophenyl trichloroacetate
4-phenoxyphenyl trichloroacetate
4-benzyloxyphenyl trichloroacetate
4-nitrophenyl trichloroacetate
pentachlorophenyl trichloroacetate
4-trifluoroethenyl phenyl trichloroacetate
2,3,5-trichlorophenyl trichloroacetate
2,4,6-trimethylphenyl trichloroacetate
2,3,4,5-tetrachlorophenyl trichloroacetate
4-nitro-3-trifluoromethylphenyl trichloroacetate
3-trichloromethylphenyl trichloroacetate, and
4-vinylphenyl trichloroacetate. The corresponding tribromoacetate, trifluoroacetate, and mixed halo trihaloacetate compounds are also suitable as starting material. The 4-halosubstituted and the 2,4-dihalosubstituted trichloroacetates are preferred starting materials.
The substituted phenyl trihaloacetates are a known class of compounds. They are conveniently prepared by well-known techniques. For example, the mono-, di-, and tri- chlorophenyl esters of trichloroacetic acid can be prepared by the reaction described by B. Sledzenski, L. Creslakova and R. Malinowski, in Przem. Chem. 50, 171 (1971); Chemical Abstracts, 75:5379 (1971).
The pyrolysis of the substituted phenyl trihaloacetates is preferably carried out in the vapor phase. In this embodiment, liquid phenyl trihaloacetate in a stream of dry inert carrier gas (e.g. nitrogen) is heated to sufficient temperature to vaporize the substituted phenyl trihaloacetate. The vaporized material and carrier gas are then heated at a temperature sufficient to pyrolyze at least a portion of the vaporized substituted phenyl trihaloacetate. Generally, the higher the pyrolysis temperature the greater the likelihood of forming undesirable secondary products. Consequently, a pyrolysis temperature for the vapor phase reaction of from about 300° to about 750° C. is normally used. Preferably the pyrolysis temperature is from about 450° to about 650° C. More preferably the pyrolysis temperature is from about 450° C. to about 500° C.
The pyrolysis is preferably conducted under anhydrous conditions in the presence of an inert contacting medium such as glass rings, activated charcoal, graphite, mixtures thereof, and the like. More preferably the pyrolysis is conducted in the presence of a catalyst. The inorganic salts of strong Lewis acids and weak bases are suitable pyrolysis catalysts. Illustrative examples of such catalysts include, for example, PdCl 2 , SrNiPO 4 , FeCl 3 , CaSO 4 , Ca 3 (PO 4 ) 2 , BaCl 2 , CaCl 2 , SrCl 2 , KF, LaCl 3 , ZrOCl 2 , MgCl 2 , mixtures thereof, and the like. The use of a catalyst or contact medium is preferred because it advantageously lowers the required pyrolysis temperature, increases the yield of desired product, and allows for better selectivity in producing the desired product.
The pyrolysis is preferably carried out at substantially atmospheric pressure, however, greater or lesser pressures may be used, as desired.
The invention will be readily understood with reference to the following examples which are illustrative of the present invention.
EXAMPLE 1
Part A--Preparation of 4-chlorophenyl trichloroacetate
A 25.6 gram (g) (0.2 mole) sample of 4-chlorophenol was mixed with 40 g of trichloroacetyl chloride at room temperature. The resulting solution was heated under reflux conditions at 120° C. for 10 hours. The temperature was gradually increased to 180° C. over a period of 16 hours. The reaction mixture was then allowed to cool to room temperature. An insoluble solid product was collected by filtration and dried in vacuo. The solid was identified by vapor phase chromatography as 4-chlorophenyl trichloroacetate.
Part B--Preparation of 4-chlorobenzotrichloride
The 4-chlorophenyl trichloroacetate prepared in Part A was metered into a vaporization chamber at a rate of about 1 milliliter per minute (6×10 -3 moles per minute) along with 12×10 -3 moles per minute of nitrogen and heated to about 300° C. The heated mixture was passed through a reactor at the indicated rate thereby providing a reactor residency time of about 1.2 seconds.
The reactor was a tubular structure constructed of Vycor® brand glass and having an outside diameter of about 1 inch; an inside diameter of about 3/4 inch and a length of about 36 inches. The interior of the reactor was packed with Vycor® glass rings. The reactor temperature was controlled at 550° C. by a Pyrovane controller. The effluent gases from the reactor were passed through a water cooled condenser. The condensed reaction product was analyzed by vapor phase chromatography and was found to contain 48 percent by volume of the desired 4-chlorobenzotrichloride. The complete analysis of the reaction product and the operating conditions are described in Table 1.
EXAMPLES 2-20
In a manner substantially identical to that described in Example 1, various starting materials were pyrolyzed by the method of the present process. The starting material and reaction conditions are described in detail in Table 1.
The examples illustrate the variety of contact medium, catalysts, and reaction conditions that can be used in the present process to achieve a consistently high yield of the desired substituted benzotrihalides. A comparison of examples 4 and 12 illustrates the advantageous use of an inorganic salt as reaction catalysts.
TABLE 1__________________________________________________________________________Pyrolysis of Substituted Phenyl Triahaloacetates % GLC Analysis of Reaction Products Ratio of Conver- % (In Area Percent) Primary sion Yield* Secon- to Secon- of of Starting Temp. Primary dary Ternary Starting Un- dary Starting PrimaryEx. Material Catalyst °C. Product Product Product Material known Products Material Product__________________________________________________________________________1 4-CCl.sub.3 Vycor 550 4-ClφCCl.sub.3 4-Cl.sub.2 φ 4-CCl.sub.3 64.8 4.6 1.5 35.2 48.3 CO.sub.2 φCl Ring OφCl 17.0 11.6 2.02 4-CCl.sub.3 PdCl.sub.2 500 4-ClφCCl.sub.3 4-Cl.sub.2 φ -- 68.2 3.2 21.0 31.8 85.8 CO.sub.2 φCl (0.5%) on 27.3 1.3 Act. Char- coal (mesh 10-20)3 4-CCl.sub.3 PdCl.sub.2 550 4-ClφCCl.sub.3 4-Cl.sub.2 φ -- 60.5 5.1 4.7 39.5 71.9 CO.sub.2 φCl (0.5%) on 28.4 6.0 Act. Char- coal (mesh 10-20)4 4-CCl.sub.3 Act. Char- 550 4-ClφCCl.sub.3 4-Cl.sub.2 φ -- 55.0 12.6 3.3 45.0 55.1 CO.sub.2 φCl coal (4-12 24.8 7.6 mesh)5 4-CCl.sub.3 1/4" Graph- 500 4-ClφCCl.sub.3 4-Cl.sub.2 φ 4-CCl.sub.3 51.2 10.4 5.8 48.8 64.3 CO.sub.2 φCl ite Pellets OφCl 31.4 5.8 1.26 4-CCl.sub.3 1/4" Graph- 510 4-ClφCCl.sub.3 4-Cl.sub.2 φ 4-CCl.sub.3 O 64.3 6.1 6.7 35.7 69.5 CO.sub.2 φCl ite Pellets φCl 24.8 3.7 1.17 4-CCl.sub.3 1/4" SrNiPO.sub.4 500 4-ClφCCl.sub.3 4-Cl.sub.2 φ 4-CCl.sub.3 O 58.6 12.7 28.0 43.4 64.2 CO.sub.2 φCl Pellets φCl 27.9 1.0 1.48 4-CCl.sub.3 SrNiPO.sub.4 500 4-ClφCCL.sub.3 4-Cl.sub.2 φ 4-CCl.sub.3 O 22.3 48.5 1.2 77.7 19.8 CO.sub.2 φCl φCl 15.4 12.8 1.09 4-CCl.sub.3 2% FeCl.sub.3 on 450 4-ClφCCl.sub.3 4-Cl.sub.2 φ 4-CCl.sub.3 O 51.3 18.6 24.0 48.7 54.6 CO.sub.2 φCl Graphite φCl 26.6 1.1 0.410 4-CCl.sub.3 CO.sub.2 φCl CaSO.sub.4 (8 mesh) 500 4-ClφCCl.sub.3 4-Cl.sub.2 φ ##STR5## 3.4 15.3 .1 96.6 1.0 0.9 15.3 65.011 4-CCl.sub.3 CO.sub.2 φCl Ca.sub.3 (PO.sub.4).sub.2 (4-12 mesh) 480 4-ClφCCl.sub.3 4-Cl.sub.2 φ ##STR6## 47.3 5.6 2.5 52.7 60.3 31.8 12.6 2.812 4-CCl.sub.3 BaCl.sub.2 on 470 4-ClφCCl.sub.3 4-Cl.sub.2 φ 4-CCl.sub.3 O 37.5 8.4 7.7 62.5 75.4 CO.sub.2 φCl 4-10 mesh φCl Act. Char. 47.2 6.1 0.813 4-CCl.sub.3 CaCl.sub.2 490 4-ClφCCl.sub.3 4-Cl.sub.2 φ -- 24.0 4.5 6.5 76.0 81.6 CO.sub.2 φCl (4 mesh) 62.0 9.514 4-CCl.sub.3 CaCl.sub.2 490 4-ClφCCl.sub.3 4-Cl.sub.2 φ -- 31.0 5.5 6.0 69.0 79.7 CO.sub.2 φCl (4 mesh) 55.0 8.515 4-CCl.sub.3 CaCl.sub.2 490 4-ClφCCl.sub.3 4-Cl.sub.2 φ -- 35.0 5.0 5.7 65.0 80.0 CO.sub.2 φCl (4 mesh) 52.0 8.016 CCl.sub.3 CO.sub.2 Activated 550 2,4-diCl- 1,2,4-tri- Cl.sub.2 φOH 80.2 3.6 2.3 19.8 50.0 φCl.sub.2 Charcoal benzo Clφ (mesh 4-12) trichloride 9.9 4.3 2.017 CCl.sub.3 CO.sub.2 1/4" Graph- 500 2,4-diCl- 1,2,4-tri- CCl.sub.3 O 56.0 5.5 2.3 44.0 56.2 φCl.sub.2 ite Pellets benzo Clφ φCl.sub.3 0.6 trichloride Cl.sub.2 φOH 2.4 24.7 10.818 CCl.sub.3 CO.sub.2 1/4" Graph- 500 2,4-diCl- 1,2,4- CCl.sub.3 O 66.2 3.0 5.5 33.0 68.0 φCl.sub.2 ite Pellets benzo tri- tri-Clφ φCl.sub.2 0.6 chloride Cl.sub.2 φOH 3.0 23.0 4.219 4-CF.sub.3 CO.sub.2 -- 650 4-ClφCF.sub.3 4-Cl.sub.2 φ -- 87.8 3.3 8.8 12.2 65.6 φCl 8.0 0.920 CCl.sub.2 CO.sub.2 CaCl.sub.2 465 2,4-diCl 1,2,4- CCl.sub.3 COCl 28.0 -- 2.6 80.0 50.0 φCl.sub.2 (4 mesh) benzotri- Cl.sub.3 φ chloride 40.0 15.0 17.0__________________________________________________________________________ Notes: *% yield based on material converted 4-CCl.sub.3 CO.sub.2 φCl = 4chlorophenyl trichloroacetate 4-Cl.sub.2 φ = 1,4-dichlorobenzene 4-CCl.sub.3 φCl = 4chlorobenzotrichloride 4-CCL.sub.3 OφCl = 4trichloromethoxy chlorobenzene ##STR7## CCl.sub.3 CO.sub.2 φCl = 4chlorophenyl trichloroacetate 1,2,4-triClφ = 1,2,4-trichlorobenzene Cl.sub.2 φOH = 2,4dichlorophenol CCl.sub.3 OφCl.sub.2 = 2,4dichlorophenyl trichloromethyl ether 4-CF.sub.3 CO.sub.2 φCl = 4chlorophenyl trifluoroacetate 4-ClφCF.sub.3 = 4chlorobenzo trifluoride | Benzotrihalides are prepared by pyrolyzing a substituted phenyl trihaloacetate of the formula ##STR1## wherein each X is halo, nitro, alkyloxy, aryloxy, aralkyoxy, cyano, lower alkyl, haloalkyl, haloalkyloxy, alkenyl, haloalkenyl, carbamoyl, N,N-dialkylcarbamoyl, N,N-diarylcarbamoyl, or N,N-diaralkyloxy;
Y is halo; and
n is an integer of from 1 to 5. As an example, 4-chlorophenyl trichloroacetate is pyrolyzed at 550° C. to 4-chlorobenzotrichloride. | 2 |
BACKGROUND OF THE INVENTION
This invention relates to structural assemblies and is particularly concerned with curtain walling or cladding and architectural constructions comprising such walling or cladding, and with building components for use in such constructions.
Typically, architectural constructions using curtain walling may employ horizontal load-bearing structural members at successive levels, e.g. in the form of concrete floor slabs cast in situ and possibly with vertical extensions or stands at the outer edge of each floor slab, to which members the curtain wall is secured by tie-back elements, such as metal ties so that it spans the successive levels to form an outer wall of the building, typically being many storeys high. Although the curtain walling does not have to bear the main vertical loads of the building it must be able to withstand wind force bending loads, for which purpose vertical mullions of the curtain wall usually have a deeper section than transoms extending between them, and their rear faces lie close to, although they are at a spacing from the floor slabs.
In this form of construction the means connecting the mullions to the floor slabs may substantially close said spacing between them but the relatively large gap between the floor slabs and the rear face of the curtain wall between mullions must be filled with a suitable fire-resistant material, because closure of the gap between the floor slabs and the curtain wall is needed to prevent or delay the progress of flames and smoke upwards from one floor to the next in the event of a fire. The inserted filling must moreover be supported in such a way that it is then held in place, when the stability and integrity of the curtain walling itself cannot be relied upon because of the effects of the fire. In other words, it is normally necessary to ensure that there is a fire-resistant barrier adequately held in place at each level of the main horizontal structural members in order to satisfy fire-resistance requirements.
It has been proposed (U.K. Pat. No. 962,790) to provide fire-resistant building panels as part of the curtain walling, these panels comprising parallel spaced asbestos boards with a heat-insulating filling between them and the outer board having a metal cladding on its external surface. To ensure they remain in place in the event of fire, these panels are required to be mounted directly to the floor slabs, which can result in fitting problems during erection of the curtain walling, and a gap is still left at the periphery of the floor slabs which must be filled by further fire resistant material to hinder the spread of flames and smoke between floors of the building.
SUMMARY OF THE INVENTION
According to one aspect of the present invention, in a structural assembly comprising a curtain wall framework having means securing it to a supporting structure comprising at least one floor slab or other horizontally extending load-bearing member, said framework being spaced from said member, there is provided a plurality of fire-resistant members interposed between the framework and said load-bearing member and supported from said member, said fire-resistant members overlying mullion members of said curtain wall framework. Said fire-resistant members may take the form of frames or panels and preferably extend vertically beyond the height of said horizontal structural member or the height of the main area of the said member.
According to another aspect of the present invention, in a structural assembly comprising a curtain wall framework having means securing it to a supporting structure comprising at least one floor slab or other horizontally extending load-bearing member, said framework having vertically extending mullion members through which wind loads on the curtain wall are to be transmitted to said at least one horizontal structural member and being spaced from said at least one structural member, said assembly also comprises a plurality of additional members that are interposed between said mullion members and said at least one load-bearing member and that each occupies a substantially greater vertical extent than its associated horizontal load-bearing member, said interposed members contacting and supporting the curtain wall framework over at least a substantial part of their vertical extent so as to reduce the bending forces on said mullion members of the framework generated by said wind loads.
It will be appreciated that in this aspect of the invention said interposed members may take also the form of frames or panels and may be so arranged as to combine both the supporting and fire safety functions referred to. Such members may conveniently be preformed from fire-resistant materials having suitable strength characteristics, for example being cast as blocks of glass-reinforced concrete. Advantageously the internal spaces of said members may be filled with a lightweight thermal insulation, so that they fulfil the further function of improving the insulation of the interior of the building.
Advantageously, the support and/or fire-resistant members are engaged and supported by tie-back elements connecting the mullions or other framework members to said at least one horizontal load-bearing member. Thus, they may have recesses or apertures through which said tie-back elements extend to support them. In a preferred arrangement, such recesses are so provided at their lateral margins that when they are placed over the tie-back elements they are supported both laterally and vertically.
For ease of construction, the assembly is so arranged as to allow some space to be left between the supporting and/or fire-resistant members and the adjacent outer edges of said at least one load-bearing member. It is possible for integral rearwards projections to extend from said members over the outer edges of said load-bearing member, leaving relatively small vertical gaps that can be filled by screed or sealing compounds, but alternatively fire-resistant closure elements can extend outwards from said load-bearing member to close the gap after assembly. In this latter case, preferably there are separate series of closure elements both at the upper and lower surfaces of the or each said load-bearing member. Said closure elements may have respective upper and lower portions that engage with correspondingly spaced portions of the supporting and/or fire-resistant members and it may be arranged that the elements form horizontally extending chambers or ducts above and/or below said load-bearing member. With respective series of elements above and below a floor slab that forms the load bearing member, and providing such ducts in both positions, the duct above the floor slab can contain space heating means and the duct below it can contain electrical cables, e.g. for ceiling lighting and other service installations of the building.
It may also be arranged that the supporting and/or fire-resistant members serve a further function as supports for inner glazing elements that form an insulating space between themselves and the glazing or other infill of the curtain wall framework or its outer face. If said members comprise heat-insulating material as already mentioned, the inner glazing elements will enhance the thermal insulation of the construction in the area of the wall construction beyond the extent of the members to give a more uniform insulating effect. The thermal insulation value of the structural assembly can be further improved if the infill at the outer face of the curtain wall framework is of a sandwich or double-glazed form.
Embodiments of the invention are described by way of example with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an outline front elevation of a part of a multi-storey structural assembly,
FIG. 2 is a sectional view to a larger scale on the line A--A in FIG. 1,
FIGS. 3 and 4 are sectional views on the lines B--B and C--C in FIGS. 2 and 3 respectively, and
FIGS. 5 and 6 are each a sectional view in the same plane as the section A--A in FIG. 2 and illustrate two modified forms of the structural assembly of that earlier figure.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 illustrates in general outline a curtain wall assembly on a building structure comprising a series of load-bearing concrete floor slabs 2 each some 25 cm thick. The curtain wall comprises a framework, with members conveniently formed by extruded aluminium sections, including mullions 4 which may each extend vertically over the height of two or more floors of the building and shorter transoms 6 extending between and secured to adjacent mullions. A series of cells, each some 3 meters high, so formed by the framework contain an infill 8 of panels and/or window panes secured in place by peripheral sealing means 12 (FIG. 2) mounted on the framework. The curtain wall is itself connected to and supported by the floor slabs 2 through tie-back elements 14 to which the mullions are secured.
FIGS. 2 to 4 show how, in accordance with the present invention, additional members 20 are interposed between the curtain wall framework and the floor slabs, in this example being in the form of panels that extend both above and below the floor slabs and providing both support and fire resistance. The panels are mounted on mild steel angle brackets 22 which form the tie-back elements, having rear flanges 24 secured by bolts 26 to the edge of the floor slab and front flanges 28 projecting forwards of the panels and secured to the sides of the mullions by bolts 30.
The panels 20 form a continuous series along the edge of each floor slab. They have recesses 32 in their side edges intermediate their height, through which the front flanges 28 of the tie-back angle brackets project. Each panel extends between a pair of mullions 4 and is therefore held at both ends by the tie-back brackets 22. Since the bracket flanges 28 fit closely within the top and bottom of each recess 32 as well as its side face, the panels are securely located both vertically and laterally without relying upon the curtain wall framework, which will normally be a relatively light construction.
The panels are themselves of a fire-resistant nature, being precast from glass-fibre reinforced concrete with internal chambers 36 filled with a thermal insulation material 38 such as mineral wool. Because of their thin walls and the lightweight insulating infill, they are therefore relatively easily handled despite their size. As a further thermal insulation measure the interiors of the hollow-section mullions and transoms may also be filled with an insulant such as mineral wool.
There will normally be a gap between the rear of the panels and the outer edges of the floor slab, although not a large one, it being required mainly to allow for dimensional deviations due to construction tolerances. The gap is closed, after the panels are assembled in place, by respective upper and lower steel angle members 40 bolted to the floor slab 2. The provision of a sealing compound in the areas 42 between the front faces of the angle members and the panel and the areas 44 between the adjoining side edges of the panels themselves completes the closure of the gap between floor slab and curtain wall in a manner that affords a suitable degree of fire resistance.
The panels extend some substantial distance above and below the floor slabs and therefore can assume the function of conventional upstands and downstands at the edge of the slabs as flame barriers. The vertical extent of the panels will be dictated by architectural and fire requirements, but as an example of current building practice they may project approximately 11/2 m above and 11/2 m below the floor slab. It will be noted that they are located relative to the floor slabs by the mild steel brackets 22 and are therefore able to be supported stably in the event of fire even if the aluminium curtain wall framework and its infill are damaged.
The infill at the outer face of the curtain wall comprises sandwich and/or double-glazed panels 50. These panels can be mounted in known forms of sealing means 12, such as are described in British Pat. Nos. 1,211,881 and 1,459,401. In addition, the top and bottom edges of the panels provide support for auxiliary cill members 52 that mount internal glass sliders 54 so that a further sound and heat insulating space is provided between the sliders and the double glazing 50 mounted in the curtain wall frame. The auxiliary sill members 52 are extruded aluminium sections, like the curtain wall main frame members 4,6, and have a hooked engagement 56 with the transoms 6 as well as being secured by fixing screws 58 to the top and bottom edges of the panels 20. Conveniently both top and bottom cill members have the same section, which in the illustrated example includes a rear flange 60 that can serve as a deflector strip for a space-heating radiator placed adjacent the panels and/or as an attachment flange for duct covers (not shown).
In the main frame members of the curtain wall structure the mullions 4 and transoms 6 can have virtually identical sections, except that where provision is made for the auxiliary sill members 52 as described, the elements on the transoms for the hook engagements 56 preferably project rearwards of the mullion section. The co-acting elements of the auxiliary sill members can therefore extend continuously where these members cross the rear faces of the mullions, but it would alternatively be possible for the transoms to be identical to the mullions and for these elements to be interrupted or relieved at their junction with the mullions. In any event, because of the supporting effect of the panels the mullions can have a relatively small depth (front to rear) despite their substantial vertical extent and despite the fact that they provide the connections between the curtain wall and the load-bearing floor slabs.
This is because the panels lessen the effects on the mullions of wind loads acting on the face of the curtain wall. In a conventional curtain wall construction with the mullions supported only at the level of each floor slab, the complete span of each mullion between successive floor slabs relies upon its own bending stiffness to resist the wind loads imposed upon it. In the illustrated construction, with the rear face of each mullion engaging the considerable vertical extent of its abutting panel 20, the unsupported length of the mullion is considerably reduced (halved in the present example), so that there is a substantial reduction in the bending moment experienced. As a result, for a given wind loading requirement the depth of the section is able to be considerably reduced. In a similar way, the transoms are given support by the abutting edges of the panels.
FIG. 5 illustrates a modification of the construction described above. In many respects identical parts are used and are indicated by the same reference numbers.
In the arrangement of FIG. 5 the curtain wall frame structure is tied back to the wall slabs 2 as already described and the panels 20 are mounted on the tie-back brackets 22 in the same way as before, but between the panels and the floor slabs, both above and below the floor slabs, there are duct members 70, 72 respectively, of substantially continuous cross-section which function partly as alternatives for the closure angle members 40 of the first-described embodiment. Like the panels 20 the duct members can be made of glass-reinforced concrete. Sill members 74 generally similar to the members 52 now each have a rear lip 76 overlying a flange 78 of their duct members, through which securing bolts 80 pass into the panel itself, while steel ties 82 cast into the duct members are used to secure the duct members to the upper and lower faces of the floor slabs 2, with the insertion of packings 82a as required. A sealing compound can be inserted in any gap between the duct members and the upper and lower faces of the floor slabs.
The upper duct members 70 can serve to enclose space heating means, indicated schematically at 84, for the interior of the building, and for this purpose there may be provided air flow openings such as are shown at 86 and 88 in the duct member. Where required these openings may be screened, as by louvered plate 88a. The lower duct member can similarly be provided with access openings, with screens or covers if required, and may serve as trunking for cable services and the like within the building, while its lower face can be adapted to mount a false ceiling structure (not shown). The upper and lower duct members can be formed by identical mouldings or castings and both are shown with an integral core 90 of a material able to provide a secure fixing for items such as the space heaters 84.
FIG. 6 illustrates another construction that is similar in many respects to that shown in FIGS. 2 to 4. In this instance, however, there are supporting and fire-resistant panels 100 that have integrally cast or moulded rear ribs or flanges 102 that make it possible to dispense with separate closure members for the gap at the edge of the floor slabs. In their other details the panels 100 can be identical to the panels 20. The spacing between the flanges 102 is slightly greater than the floor slab thickness, but the upper and lower gaps resulting from this are each less than the maximum gap at the edge of the floor slab that must be allowed for in the previously described construction.
On the upper face of the floor slab 2, there will normally be a screed layer 104 that provides a base for the final floor covering and this layer is spread up to and under the adjacent flange 102 to fill the gap there. On the under face of the floor slab a fireproof sealing material 106 is inserted to fill the gap. | A structural assembly, e.g. a curtain-walled building, comprises load-bearing floor slabs at successive levels and a framework of the curtain wall has vertical mullion members through which it is secured to the floor slabs at a spacing from the floor slabs. Fire-resistant panels are interposed in the gaps to check the passage of smoke and flames between floors. The panels overlie the rear faces of the mullions over a depth substantially greater than that of the floor slabs and bear against said rear faces to reinforce the mullions against wind loads. Any residual spacing between the panels and the floor slabs can be closed by fire-resistant elements that also form service ducts. | 4 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] Not Applicable
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable
DESCRIPTION OF ATTACHED APPENDIX
[0003] Not Applicable
BACKGROUND OF THE INVENTION
[0004] This invention relates generally to the field of consumer electronics and more specifically to a machine for Audio/Video Stereo Receiver with Multiple Tone Controls. In this new receiver design, separate tone control, usually treble and bass, is placed in the front panel for each of the connected component. The user now has to set the desired tone for each connected component only once. Also, the back panel, where component plug-in area is located, is slanted (about a 45 degree angle), with the panel facing upward diagonally. So the user can easily identify the correct plug-ins from all direction. Each component plug-in is situated straight behind each of the component's front panel strip. The result is that the job of connecting or disconnecting different components to the receiver has become easy and simple.
[0005] In all the existing stereo components, various input sources such as CD/DVD player, VCR, TV, etc., are connected to the receiver in the back panel. The tone of all these sound sources is controlled by a single set of equalizers in the front panel, usually treble and bass. But this kind of existing design necessitates undue efforts in adjusting the tone of various sound sources, which often demands distinctively different tones. For example, when listening to a music CD, strong bass sound is usually preferred. So the user steps over to the receiver and turns up the bass button. But when watching TV news and hearing the TV anchor's human voice, big bass sound makes the voice unnatural. Now, the user is very likely to step over to the receiver again and turn down the bass button. In other words, with existing receiver designs, the listener is likely to walk over and adjust the treble and bass every time a different type of source is heard, whether it be TV news, music CD, DVD movie or other. Also, the existing receivers are almost uniformly in square box shape. In this square box shape, the back panel, where component plug-ins are located, is perpendicular from either top or bottom of the receiver box. Consequently, each of the plug-ins is not easily visible separately by the user, who will normally look down at the receiver from a standing position. The user almost invariably has to step behind the receiver, which may usually be placed close to the wall, to locate the correct plug-ins for each component. This cumbersome and awkward work has to be done every time a different component is connected to the receiver.
BRIEF SUMMARY OF THE INVENTION
[0006] The primary object of the invention is to provide a separate tone control—treble and bass—for each connected component.
[0007] Another object of the invention is to eliminate the necessity of having to adjust the tone every time a different component is heard.
[0008] Another object of the invention is to make the necessity of adjusting tone control for each connected component only once.
[0009] A further object of the invention is to make the work of connecting various components to the receiver easier, with a slanted back panel where component plug-ins are located.
[0010] Other objects and advantages of the present invention will become apparent from the following descriptions, taken in connection with the accompanying drawings, wherein, by way of illustration and example, an embodiment of the present invention is disclosed.
[0011] In accordance with a preferred embodiment of the invention, there is disclosed a machine for Audio/Video Stereo Receiver with Multiple Tone Controls that has features of: a. Front panel that includes a number of component strips, in addition to the traditional functions such as volume control, balance control and system on/off switch; and b. Back panel that is partly slanted.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The drawings constitute a part of this specification and include exemplary embodiments to the invention, which may be embodied in various forms. It is to be understood that in some instances various aspects of the invention may be shown exaggerated or enlarged to facilitate an understanding of the invention.
[0013] FIG. 1 is a front view of the invention.
[0014] FIG. 2 is a side view of the invention.
[0015] FIG. 3 is a back view of the invention.
[0016] FIG. 4 is a perspective view of the invention.
[0017] FIG. 5 is a front view of the invention, with various components connected along with loud speakers.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0018] Detailed descriptions of the preferred embodiment are provided herein. It is to be understood, however, that the present invention may be embodied in various forms. Therefore, specific details disclosed herein are not to be interpreted as limiting, but rather as a basis for the claims and as a representative basis for teaching one skilled in the art to employ the present invention in virtually any appropriately detailed system, structure or manner.
[0019] In the machine for Audio/Video Stereo Receiver with Multiple Tone Controls:
[0020] In FIG. 1 and FIG. 4 ,
10 is lower section of the front panel. 11 is upper section of the front panel. 12 is master volume control of the receiver 13 is balance control of the receiver. It pans the stereo sound of the connected component(s) to the loud speaker on the left or on the right. 14 is AM/FM radio strip. 15 is treble control button for the AM/FM radio strip. More high tone is produced if turned right and high tone is reduced if turned left. 16 is bass control button for the AM/FM radio strip. More low tone is produced if turned right and low tone is reduced if turned left. 17 is display for the selected radio station and other useful functions, such as selected component strips and clock. 18 is tuning control for AM/FM radio 19 is FM mode selection button. When pressed on, FM radio is selected. When pressed off, FM radio is deselected. 20 is AM radio selection button. When pressed on, AM radio is selected. When pressed off, AM radio is deselected. 21 is on/off switch for the AM/FM radio strip. When pressed on, AM/FM radio strip is turned on. It then activates the treble and bass controls of the AM/FM radio strip and connects the radio signals to the receiver's main circuitry, and sound is transmitted to the loud speakers that are connected to the speaker terminals in the receiver's back panel. When pressed off, AM/FM radio strip is turned off and deactivates the treble and bass controls of the AM/FM radio strip, and radio signals are disconnected from the receiver's main circuitry and no sound is transmitted to the loud speaker. 22 is system power on/off switch. 23 is first component strip, TV in this drawing. Using proper connecting material such as RCA cables, the audio outs of the TV can be hooked up to the appropriate inserts in the slanted plug-in area in the receiver's back panel. 24 is treble control button for the TV strip. 25 is bass control button for the TV strip. 26 is on/off switch for the TV strip. When pressed on, TV strip is turned on. It then activates the treble and bass controls of the TV strip, and connects sound signals coming from TV to the receiver's main circuitry, and sound is transmitted to the loud speakers that are connected to the speaker terminals in the receiver's back panel. When pressed off, TV strip is turned off and deactivates the treble and bass controls of the TV strip, and sound signals coming from TV are disconnected from the receiver's main circuitry and no sound is transmitted to the loud speaker. 27 is second component strip, DVD/CD in this drawing. Using proper connecting material such as RCA cables, the audio outs of the DVD/CD player can be hooked up to the appropriate inserts in the slanted plug-in area in the receiver's back panel. 28 is treble control button for the DVD/CD strip. 29 is bass control button for the DVD/CD strip. 30 is on/off switch for the DVD/CD strip. When pressed on, DVD/CD strip is turned on. It then activates the treble and bass controls of the DVD/CD strip, and connects sound signals coming from DVD/CD player to the receiver's main circuitry, and sound is transmitted to the loud speakers that are connected to the speaker terminals in the receiver's back panel. When pressed off, DVD/CD strip is turned off and deactivates the treble and bass controls of the DVD/CD strip, and sound signals coming from DVD/CD player are disconnected from the receiver's main circuitry and no sound is transmitted to the loud speaker. 31 is third component strip, VCR in this drawing. Using proper connecting material such as RCA cables, the audio outs of the VCR player can be hooked up to the appropriate inserts in the slanted plug-in area in the receiver's back panel. 32 is treble control button for the VCR strip. 33 is bass control button for the VCR strip. 34 is on/off switch for the VCR strip. When pressed on, VCR strip is turned on. It then activates the treble and bass controls of the VCR strip, and connects sound signals coming from VCR player to the receiver's main circuitry, and sound is transmitted to the loud speakers that are connected to the speaker terminals in the receiver's back panel. When pressed off, VCR strip is turned off and deactivates the treble and bass controls of the VCR strip, and sound signals coming from VCR player are disconnected from the receiver's main circuitry and no sound is transmitted to the loud speaker. 35 is fourth component strip, Computer in this drawing. Using proper connecting material such as 3.5 mm cable, the audio outs of the Computer can be hooked up to the appropriate insert in the slanted plug-in area in the receiver's back panel. 36 is treble control button for the Computer strip. 37 is bass control button for the Computer strip. 38 is on/off switch for the Computer strip. When pressed on, Computer strip is turned on. It then activates the treble and bass controls of the Computer strip, and connects sound signals coming from the main board or sound card of the Computer to the receiver's main circuitry, and sound is transmitted to the loud speakers that are connected to the speaker terminals in the receiver's back panel. When pressed off, Computer strip is turned off and deactivates the treble and bass controls of the Computer strip, and sound signals coming from Computer are disconnected from the receiver's main circuitry and no sound is transmitted to the loud speaker. 39 is fifth component strip, Guitar/Keyboard in this drawing. Using proper connecting material such as ¼ inch cable, the sound outs of the guitar or keyboard can be hooked up to the appropriate insert in the slanted plug-in area in the receiver's back panel. 40 is treble control button for the Guitar/Keyboard strip. 41 is bass control button for the Guitar/Keyboard strip. 42 is on/off switch for the Guitar/Keyboard strip. When pressed on, Guitar/Keyboard strip is turned on. It then activates the treble and bass controls of the Guitar/Keyboard strip, and connects sound signals coming from the guitar or keyboard to the receiver's main circuitry, and sound is transmitted to the loud speakers that are connected to the speaker terminals in the receiver's back panel. When pressed off, Guitar/Keyboard strip is turned off and deactivates the treble and bass controls of the Guitar/Keyboard strip, and sound signals coming from Guitar/Keyboard are disconnected from the receiver's main circuitry and no sound is transmitted to the loud speaker.
[0054] In FIG. 3 ,
50 is back panel. 51 is first component plug in area, TV in this drawing. 52 is first component audio cable inserts, RCA cable inserts for TV in this drawing. 53 is second component plug in area, DVD/CD player in this drawing. 54 is second component audio cable inserts, RCA cable inserts for DVD/CD player in this drawing. 55 is third component plug in area, VCR in this drawing. 56 is third component audio cable inserts, RCA cable inserts for VCR in this drawing. 57 is fourth component plug in area, Computer in this drawing. 58 is fourth component audio cable insert, 3.5 mm cable insert for Computer in this drawing. 59 is fifth component plug in area, Guitar/Keyboard in this drawing. 60 is fifth component audio cable insert, ¼ inch cord insert for Guitar/Keyboard in this drawing. 61 is speaker terminals 62 is AC power outlet
[0068] While the invention has been described in connection with a preferred embodiment, it is not intended to limit the scope of the invention to the particular form set forth, but on the contrary, it is intended to cover such alternatives, modifications, and equivalents as may be included within the spirit and scope of the invention as defined by the appended claims. | A machine for Audio/Video Stereo Receiver with Multiple Tone Controls. In addition to the system power switch, master volume control and balance control, the front panel of the receiver is further divided into a number of component strip areas. Each component strip has its own tone controls—usually treble and bass. There is on/off switch on each component strip, to connect or disconnect to the main circuitry of the receiver. Component plug-ins, located in the back panel of the receiver, are positioned straight behind each component strip located in the front panel of the receiver. The back panel, where component plug-ins are located, is slanted (about 45 degrees), with the component plug-ins facing diagonally upward. | 7 |
CROSS-REFERENCE TO CORRESPONDING APPLICATIONS
This application is a continuation-in-part of application Ser. No. 332,130 (now abandoned) Feb. 13, 1973 as a division of application Ser. No. 107,304, filed Jan. 18, 1971 and now U.S. Pat. No. 3,755,037.
BACKGROUND OF THE INVENTION
This invention relates to the manufacture of rackets, and particularly to tennis rackets although the principles thereof are applicable to any type of strong racket, e.g. squash rackets.
Throughout most of the history of racket sports, all good rackets were made primarily of wood, generally in the form of a plurality of curved pieces laminated together by glue or the like. These rackets possessed many desirable qualities from the standpoint of strength, but also were subject to certain disadvantages. For example, wood is of variable quality at best, and wood of the best quality is increasingly scarce. In any event, wood is subject to warping and to fatigue, particularly under the stress of tightly stretched strings, and accurate control of weight, and especially of balance, was difficult.
Comparatively recently, the art has produced rackets wherein the frame is constructed of steel or aluminum. Obviously, a racket frame of such a material does not warp and possesses a very high degree of strength, but the initial cost of materials, as well as the cost of the equipment for forming the metal racket frames, is high, thereby making the consumer cost of such a racket high. Further, metal frames have problems of cracking of welds, and with physical properties of density, strength and stiffness tending to result in rackets which are too flexible.
The use of glass reinforced plastic materials has become widespread during this same period of time. It is well known that the glass reinforced plastics have a very high strength, they have a good modulus of elasticity, the raw materials are inexpensive, and they can be readily formed and otherwise handled. The use of glass reinforced plastic in a tennis racket frame was proposed as long ago as 1949, in Robinson U.S. Pat. No. 2,878,020. Yet in spite of this knowledge and early suggestion, the art has been unable to develop a satisfactory racket frame formed of fiber reinforced plastic material.
SUMMARY OF THE INVENTION
The racket frame provided by the invention has as its primary structural member an elongated hollow tube, the wall of which consists essentially of a plurality of concentric layers of glass fiber impregnated and bonded together by binder resin. The majority of these fiber layers are helical windings of predetermined unidirectional hand with respect to the longitudinal axis of the tubular member, alternate windings being of opposite hand, but there should also be one or more layers wherein the fibers run lengthwise of the tube to provide adequate bending strength in the finished frame. This tubular member is formed in a loop so that its central portion defines the head of the racket frame, and the two end portions converge at the base of the head portion to define an open throat from which they extend in parallel relation to form the frame handle, to which a suitable grip is applied.
Special features of the frame of the invention include a groove molded in the outer end part of the head portion for receiving loop portions of the racket strings in recessed relation with the surrounding peripheral area of the frame. Special provision is also made for reinforcing the throat portion of the frame, preferably by means of a filler member positioned between the converging parts of the tube and secured in bridging relation therewith, in one form by layers of fiber and binder, and in another form by means of the racket strings.
The method of the invention by which the racket frames are produced, namely by applying successive layers of binder-impregnated fiber to a removable matrix, lends itself particularly well to the establishment of the proper strength characteristics at stress points in the frame, as well as proper characteristics of weight, balance and flexibility or stiffness which are important for the best playing qualities. For example, the windings of which the tubular member is composed can be varied in number and length to provide extra wall thickness in the head portion of the racket as compared with the handle portion. Similarly, after the tubular member has been formed to the basic racket shape, reinforcement can be provided where it may be needed, in the throat and/or handle portion, by cover layers of binder-impregnated fiber which are bonded into the integral frame during the subsequent curing of the binder.
The method by which the racket frames of the invention are produced is generally as described in our above noted Pat. No. 3,755,037, but since the filing of that original application, improvements have been made in the method, particularly in connection with the formation of the groove in the racket head which receives loop portions of the strings. The matrix upon which the successive layers of fabric are wound includes an elastomeric tube, a removable core for this tube composed of multiple wires, and a filler member which is of approximately the same length and cross section as the groove and extends along a central portion of the matrix.
When the successive fiber layers are applied to this matrix, the filler member causes the wall of the resulting tubular member to be of correspondingly greater peripheral dimensions along its central portion as compared with the portions beyond each end of the filler member. Then when the uncured tubular member is subsequently placed in a mold and expanded by the internal pressure, the greater periphery provided by the extra material in its central portion makes it possible for the tubular member to be fully molded around a rib in the mold cavity and thereby forms the groove in that portion of the tubular member which becomes the outer end portion of the head of the racket frame but without affecting the overall cross-sectional outline of the head portion of the frame.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view showing a complete racket in accordance with the invention;
FIG. 2 is a fragmentary view, partially in side elevation and partially in vertical elevation, illustrating a preliminary stage in the fabrication of the racket of FIG. 1;
FIG. 3 is an enlarged section on the line 3--3 of FIG. 2;
FIG. 4 is a further enlarged fragmentary view illustrating an intermediate stage in the fabrication of the tubular member which is the main structural part of the racket of FIG. 1;
FIG. 5 is a partial exploded isometric view illustrating the preform mold and the corresponding stage in the fabrication of the racket frame;
FIG. 6 is an exploded isometric view illustrating the operation of assembling the component parts for finally molding the racket frame;
FIG. 7 is an elevational view, partially broken away, of the racket frame following the stage of FIG. 6;
FIGS. 8, 9 and 10 are enlarged sections on the lines 8--8, 9--9 and 10--10 respectively of FIG. 7;
FIG. 11 is an enlarged fragment of the head of the complete racket of FIG. 1, partially broken away in section;
FIGS. 12 and 13 are further enlarged sections on the lines 12--12 and 13--13 of FIG. 11, respectively;
FIG. 14 is a fragmentary exploded view illustrating the assembly of the handle portion of the frame of FIG. 1;
FIGS. 15 and 16 are fragmentary elevations, partially broken away, showing modifications of the racket frame of the invention having an opening in the throat portion thereof;
FIG. 17 is a fragmentary elevational view illustrating another modified frame construction in accordance with the invention;
FIG. 18 is a fragmentary view similar to FIG. 17 illustrating still another frame construction in accordance with the invention.
FIG. 19 is a fragmentary view illustrating a modification of the method of the invention wherein the holes for the racket strings are preformed; and
FIGS. 20 and 21 are enlarged sections on the lines 20--20 and 21--21 of FIG. 19.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a complete tennis racket in accordance with the invention in which the frame includes a generally oval shaped head portion 10, a handle portion 11, and a throat portion 12 interconnecting the head and handle portions. The handle 11 is provided with a grip 13, and the head 10 carries the strings 15. As shown in FIGS. 7 and 10, the head 10 is formed with a groove 16 extending around approximately the outer end half of its periphery, and the loop portions 15' of the strings are recessed in this groove below the adjacent peripheral portions of the frame for protection in use.
The basic structural part of this racket frame is the unitary tubular member 20, which includes the loop 21 defining the head 10, the converging sections 22 defining the throat 12, and the parallel end sections 23 defining the handle 11. The only other pieces of the frame, with the exception of the grip 13, are a filler piece 25 between the throat portions 22, and a fin-like spreader member 26 extending between the handle sections 23, both of which are optional and are made of light material such as balsa wood or plastic foam. Also, grommets 27 and 28 are provided as liners for the holes which receive the strings 15, the difference between the two sets of grommets being only that the grommets 28 have straight sided heads proportioned to seat within the groove 16.
FIGS. 2-10 illustrate successive stages in the manufacture of the racket frame of FIG. 1. The first stage is the formation of a mandrel comprising an elastomeric tube 30, core wires 31 and 32, and a filler member 33. The tube 30 is preferably of a rubber material which will not disintegrate in the curing cycle of a frame, and satisfactory results have been obtained with a rubber tube having an outer diameter of 7/16 inch and a wall thickness of 1/32 inch. The length of this tube should be somewhat in excess of the final length desired for the tubular member 20.
It is possible to use only a plurality of wires 32 of small diameter, e.g. 1/16 inch, but it is quicker and easier to use also at least one wire or rod 31 of substantially larger diameter, e.g. 1/4 inch and the rod 31 is shown as provided at one end with a drive collar 36. A sufficient number of the wires 32 is used to fill the tube 30 completely, and preferably to expand it slightly, for example to an outer diameter of 5/8 inch.
The purpose of the filler member 33 is to increase the peripheral dimension of the mandrel along its portion corresponding to the part of the head in which the groove 16 is formed. The member 33 can be placed within the tube 30, but it is simpler to locate it on the outside, and this is easily done by welding a section of quarter-inch rod 33 to the middle of a carrier wire 35 of the same length as the other wires 31-32. For a full size frame, the filler member 33 may be 21 inches long. One end of the wire 35 fits in a groove in the collar 36 and is held in place by an O-ring 37. The other end is similarly held on tube 30 by a similar O-ring 37.
The completed mandrel is then mounted in a tensioning and winding apparatus as shown in FIG. 2. The shaft of a low speed drive motor 40 holds and drives the collar 36 through a pin and bayonet slot connection 41. The other end of the rod 31 is secured in a chuck 42 mounted for free rotation on an adjustable tail stock comprising a screw 44 threaded in a stand 45 and having a handle 46. Backing off of the screw 44 will provide the necessary tensioning of rod 31 to support the entire mandrel in essentially straight position.
The multiple layers of binder-impregnated fiber are then successively applied to the mandrel, which is easily done while it is being rotated by the motor 40. To some extent, the number and sequence of application of these layers may be varied, but it is important that the majority of the layers be helically wound of unidirectional hand with successive such layers being of opposite hand, and also that there be at least one layer wherein the fibers run lengthwise of the mandrel and are not twisted. It is particularly important, for optimum results from the standpoint of both proper control of weight and the proper combination of strength and resiliency in the finished racket, to use tape composed of essentially continuous parallel filaments, as distinguished from woven or braided tape or tubing. One reason for this is that in a woven (mesh) tape, the cross fibers add thickness, since the thickness of the tape doubles at each crossover, and also weight without comparable contribution to strength for the purposes of the invention. In fact, the cross fibers would add no significant strength to applicant's frame as compared with continuous filament tape, but they would double the weight and effectively double the thickness of the wall of tubular member 20 for the same number of tape layers.
Another aspect of this matter is that in a fiber mat structure, wherein relatively short fibers are held together by resin binder, load transfers are required to take place through the resin securing adjacent fibers together, and this is an inefficient use of the tensile strength of the fibers. This same deficiency would be present in helically wound mesh tape, in that the cross fibers would be relatively short, and would have to depend on the resin to transfer loads therebetween. In contrast, with unidirectional continuous filament tape would helically and with adjacent layers of opposite hand, the continuous filaments provide the most efficient transfer of loads throughout the frame, and their ability in this respect is increased when they are placed in tension in accordance with the practice of the invention as described hereinafter.
In a typical example of the practice of the invention, preferred results have been obtained by applying the following layers of binder-impregnated fiber tape one inch wide in the specified sequence:
A helical layer 50 extending slightly in excess of the full length desired for the tubular member 20, e.g. 63 inches.
A straight full length layer 51 composed of two lengths of the tape.
A second full length helical layer 52 of the opposite hand from layer 50.
Two helical layers of alternately opposite hand extending over only the central portion corresponding to the loop 21 and converging portions 22, e.g. 32 inches.
A full length helical layer 55 of the opposite hand from the adjacent under layer.
Optionally, particularly for a heavier racket frame, two helical wraps of opposite hand may be applied before the layer 55 along only the central portion of the assembly overlying the filler member 33.
As soon as winding has been completed, the assembly is removed from the winding and tensioning apparatus, and the core wires 31 and 32 are removed from within the tube 30. The filler member 33 and its carrier wire 35 are then also easily removed, but it may be simpler to remove them and the tube 30, and then to replace the tube 30 in the uncured tubular shell.
It is quicker and simpler to utilize fiber tape already impregnated with binder than to add binder resin in the mold cavity during the final molding stage, and this is particularly true for continuous filament tape because the resin holds the non-woven filaments together. The pre-impregnated tape yields more uniform products, but it tends to be sticky at room temperature, and subsequent handling is facilitated if the tubular member is refrigerated after the core wires have been removed, preferably in a preform mold 60 having a cavity 61 closely corresponding to the mold cavity in which final curing of the frame is performed. It is also desirable at this stage and process to insert a generally triangular filler member 25 in the open throat area between the converging portions 22 of the tubular member, as well as the divider strip 26 between the handle portions 23.
The final assembly and molding operations are illustrated in FIG. 6 as carried out in a mold comprising three main parts 70, 71 and 72. The mold part 70 includes the bottom and sides of the cavity 75 corresponding to the handle portion of the racket frame, the throat portion, the inside of the head portion, and that part of the outside of the head portion which does not contain the groove 16. The upper mold part 71 includes a male section 76 defining the upper wall of the cavity 75 in the part 70. The part 72 is movable horizontally toward and away from the parts 70-71 and includes a cavity defining the outside of the head portion of the frame and incorporating an internal rib 77 located and proportioned to form the groove 16.
In the final assembling steps before closing the mold and curing the tubular member 20, a crescent-shaped strip 80 of binder-impregnated fiber is set in the bottom of that portion of the cavity in mold part 70 which underlies the filler piece 25 along the inner end of the head portion 10 and adjacent portions of the loop 21. A layer 81 of the fiber material of the same dimensions as width of the handle and throat portions is then set in the bottom of the cavity. Then a strip 82 of about half the width as the handle portion of the frame is set in the cavity, along with a piece 83 matching the outline of the throat portion of the frame. Also a strip 84 is set along the side of the cavity opposite the throat portion so that it will overlie the exposed edge of the filler piece 25 in the finished frame.
The refrigerated tubular member from the mold 60 is then set in the cavity 75, with the ends of the rubber tube 30 extending to the outside through appropriate grooves 85 in the mold. The divider strip 26 can be inserted at that time if it was not inserted when the tubular member was placed in the preform mold 60. A second series of strips 80-83 is then laid on top of the tubular member, after which the mold parts 71 and 72 are moved into position to close the mold.
For efficient production, the mold parts 70-72 are maintained at the desired curing temperature, so that as soon as the mold is closed, the refrigerated binder begins to soften. When it is thoroughly softened, for example after two to three minutes, air pressure is applied to the projecting ends of the tube 30 as indicated at 88, at a sufficient pressure to expand the tubular member 20 into firm engagement with all surfaces of the mold cavity and thereby to maintain all the fiber layers in tension while the binder is setting, and particularly to cause the slack fiber material opposite the rib 77 to engage this rib evenly in order to form the groove 16. This pressure is not critical, and satisfactory results have been obtained with air at a pressure of 40 p.s.i. The temperature of the mold and the time of curing are interdependent, in accordance with standard practice for the curing of fiber reinforced plastics. As previously noted, the temperature should not exceed the level at which the tube 30 would disintegrate before the end of the initial stage of the curing cycle.
Satisfactory results have been obtained if the initial stage of the curing cycle continues for a total of 15 minutes at 275° F, after which the pressure supply to the tube 30 is discontinued, the mold is opened, the tubular member is ejected, and the tube 30 is withdrawn from its interior. Any flash or other surplus material can then be removed, after which the cure should be completed, satisfactory results having been obtained in an oven at a temperature of 250° F for a period of 3 hours.
The overall configuration of the frame after trimming and curing is shown in FIGS. 7-10 which illustrate that the fiber layers and binder effectively combine to form a solid wall in which all of the fibers are substantially uniformly tensioned for maximum strength. As best shown in FIGS. 12-13, the head portion 10 is symmetrical in sectional outline along both the grooved and non-grooved parts thereof, so that the grooved part would fit the peripheral outline of the ungrooved part, but the grooved part has a greater peripheral dimension in cross section, by reason of the extra surface provided by the fiber wall which defines the groove 16 although the thickness of the tube wall is uniform throughout the head portion 10, as shown by comparision of FIGS. 12 and 13, unless extra layers are applied overlying the filler member 33 as pointed out above. Also, the thickness of the tubular member will vary in these parts of the head portion, depending upon how many layers of fabric were wound therein.
The handle portion 11 is illustrated as having a decorative groove 90 along the portion not covered by the grip 13 in the finished racket, such groove being imparted by appropriate complementary configuration of the mold parts 70-71 as desired. The outer end of the handle portion, however, is molded to a rectangular section for easy mounting of the grip 13, which is shown as formed in two complementary molded plastic parts 91-92 held in place by two bookbinder's screws 93 extending through holes drilled in the handle portion 11, and this mounting may be reinforced by adhesive. The grip is finished conventionally by a winding 95 of leather or plastic as shown in FIG. 1, and it is apparent that other grip means can also be used, such as grips formed by molding a suitable foam material around the end of handle part 11. Otherwise completion of the racket from the stage shown in FIG. 7 is conventional, involving drilling of the necessary holes for the strings 15, insertion of the grommets 27-28, and painting as desired.
Some modifications of the basic frame configuration shown in FIG. 1 are illustrated in FIGS. 15-17. Thus FIG. 15 shows a portion of a racket frame having an opening 100 through its throat portion, and in this case, a filler piece 101 of generally crescent shape is positioned between opposed locations on the converging sections 102 of the tubular member. The fabrication of this frame follows the same steps already described, but the strips of fiber which are applied in the mold are of appropriate configuration for the final design.
The filler piece 101 in FIG. 15 may be of balsa wood or plastic foam, since it serves merely as a support in the mold for the strips of resin-impregnated fiber which carry the load in the finished racket. A strip 103 of tape should be applied in the mold to cover the inner edge surface of filler piece 101 in the same manner as the strip 104, which corresponds to strip 84 in FIG. 6. An alternative construction is shown in FIG. 16, wherein the filler piece 101 is covered by a pair of windings 105 and 106 of tape of opposite hand, the ends of which also wrap around the joining portions of piece 101 and sections 102 to provide extra strength at those joints. One or more wraps of tape can similarly be provided around the joining portions of piece 101 and sections 102 in the construction shown in FIG. 15.
FIG. 17 shows a racket frame in which the handle sections 110 of the tubular member are exposed in spaced relation between the throat portion of the racket and the grip 111. This arrangement is readily established by appropriate complementary configuration of the preform mold and of the curing mold parts, and of course no divider 26 is used in this racket. The filler piece in the throat portion of this racket frame may be of essentially the same configuration as in FIG. 5, in which event it is bonded into position by overlying layers of fiber in the same manner already described, but it is shown as a separate molded plastic piece 112 held in place by the grommets which line the holes for the racket strings and by the strings themselves. As shown, this piece 112 has integral channels 113 molded therein for the racket strings. These channels could also be molded on radii of appropriate lengths such that the string in each channel 113 would leave the channel tangent thereto and thus minimize possible abrasion between the string and the end of the channel. Otherwise, this racket frame is of essentially the same construction already described in connection with FIGS. 1-14.
FIG. 18 shows another modified construction wherein the converging portions 115 of the tubular member have no spacer or bridging means therebetween and thus define an open throat into which the strings 15' extend, the converging portions 115 having enough holes for strings to extend across most of the open throat, and all of these holes being provided with grommets 27'. Thorough testing has established that this frame construction has all necessary strength, since overlying layers of resin-impregnated fiber corresponding to the layers 81 and 82 in FIG. 6 are also used in this construction to assure bonding of the handle portions of the tubular member together up to the point at which they begin to diverge at the apex 116 of the open throat.
It can be readily appreciated from the preceding description that the invention provides a high degree of versatility in the control of the strength, weight and balance of a racket frame. Thus for a heavyweight frame, the number of windings in its tubular member can be appropriately selected, and its balance can be established, by applying extra windings where needed, or by filler material at appropriate locations within the tubular member, for example within the outer end of its head loop. Similarly, the overall design is subject to wide modification exemplified by FIGS. 15-18.
It is also possible to add to the method of invention the step of preforming the holes in the frame for the racket strings, instead of drilling them after molding is completed. This feature of the invention is illustrated in FIGS. 19-21, wherein the tubular shell 120 corresponds to the shell 20 in FIGS. 5 and 6 at the stage when it is ready for insertion in the preform mold 60 and is therefore relatively pliable and with the fibers in the successive layers relatively loosely held together.
A forming member 121 composed of a strip of flexible material includes multiple probe elements 122 arranged thereon in appropriately spaced relation corresponding to the spacing of the holes along the outer periphery of the head and throat section of the racket frame for receiving the racket strings. In addition, the forming member 121 includes a rib portion 123 corresponding in dimensions to the rib 77 in FIG. 6 which forms the groove 16 in the racket frame of FIGS. 1-13. As shown, each of the probe elements 122 is provided with a relatively sharp point, and in section, its sides are curved to produce a rounded edge for the hole formed thereby in the wall of shell 120, but its length should be such that it will penetrate only the fiber layers and not tend to puncture the tube 30 while the latter is pressurized.
A similar flexible forming member 125 is proportioned to extend around the inner periphery of the head portion of the frame and incorporates probe elements 122 in appropriately spaced relation corresponding to the spacing of the string holes on the inner side of the racket head. An additional forming member 126 is configured to extend across the inside of the throat portion of the frame, and its proportions will vary in accordance with the design of the throat portion of the finished frame. The forming member 126 is shown as designed for use in producing a throat portion as illustrated in FIGS. 5-7, with probe elements 127 designed to penetrate through the foam filler piece 25 to the interior of the throat portions of the shell 120.
It will be apparent that with a racket frame of the open throat type, the member 126 could have probe elements 122 if an additional forming member is provided for insertion in the open throat portion opposite the member 126. Similarly, if the filler piece 25 is made of wood, it would be easier to utilize a forming member 126 having probe elements 122 only long enough to penetrate the fibers overlying such filler piece. In this case, the holes formed thereby would have to be connected with their mating holes in the shell 120 by drilling through the filler piece, and the holes in the inner wall portion of the shell could also be drilled or could be preformed by special probe elements like elements 127.
In the practice of the invention as illustrated in FIGS. 19-21, the members 121, 125 and 126 are preferably applied to the shell 120 before or in connection with insertion in the preform mold as illustrated in FIG. 5. This can be done relatively easily, with the probe elements 122 being caused to pierce the shell wall by separating the fibers with minimum tendency to rupture any of the fibers. The forming members will then remain in place throughout the molding operation illustrated in FIG. 6, and they can be provided with appropriate locating means such as holes 130 positioned for engagement by locating pins in the mold or molds. During the application of heat and pressure to the shell as described, the pressure will cause the wall of the shell to conform smoothly to the forming members and their probe elements in the initial stage of the final molding operation when the binder softens preliminarily to hardening.
One advantage of this procedure is that the fibers are not cut or otherwise ruptured to form the holes for the racket strings, as they necessarily are when they are formed by drilling. This procedure also eliminates the separate drilling operation, since the only drilling necessary in the practice of the invention as illustrated in FIGS. 19-21 would be to connect opposed pairs of holes on opposite sides of a wood filler piece in the racket throat as noted above.
While the methods and articles herein described constitute preferred embodiments of the invention, it is to be understood that the invention is not limited to these precise methods and articles, and that changes may be made therein without departing from the scope of the invention. | A tennis racket frame is constructed primarily of an elongated hollow tube member having a wall thereof consisting essentially of a plurality of concentric layers of high tensile strength fibers impregnated and bonded together by binder resin, at least two of the layers being helical windings of opposite unidirectional hands, and the head portion of a racket frame having a groove molded therein to receive the loop portions of the strings in recessed relation to the surrounding surface areas of the frame. The frames are made by a method including the use of a special mandrel on which the layers of fiber are wound under controlled conditions providing extra material in the head portion which is formed into the wall of the grooved portion of the head without affecting the overall sectional dimensions of the frame. | 0 |
BACKGROUND
[0001] The present disclosure is related to display devices, and more specifically to a card or the like employing a piezoelectric charge generator for temporarily driving a display.
[0002] There are today a relatively large number of different techniques for producing electronic devices. One family of such techniques, of interest herein, is commonly referred to as printed electronics processes, and the resulting devices referred to as printed electronics. Various methods fall within the definition of printed electronics processes. Screen printing, traditional and digital lithography, flexography, gravure and jet-printing are a number of the more common of such methods. In each case, a conductive, semi-conductive or insulating material is deposited over a substrate to form interconnected passive and/or active electronic components. Printing processes typically deposit materials in the form of a solution, a slurry or a powder. Transfer processes such as thermal transfer or laser transfer processes may also be used to print structures. In a thermal transfer process, a layer such as a metal film may be transferred from a carrier substrate to another substrate. Known printed electronic processes can utilize a wide variety of materials for these components, and are not limited to organic materials.
[0003] Printed electronics processes enable the integration of electronic, optical, and other functionalities into products at potentially ultra-low cost. Printed electronic processes take advantage of known, relatively simple printing techniques, and are thus typically less expensive and often less environmentally hazardous than traditional lithography and deposition techniques. Certain materials and techniques used for printed electronics processes permit printing on non-crystalline substrates, such as paper, plastic, fabric, etc. Such processes may permit printing on flexible substrates, which is not easily done with conventional electronic device fabrication techniques. Furthermore, printing processes have been developed for non-planar surfaces, which is also a challenge for conventional electronic device fabrication techniques. However, in order to maintain low cost and/or substrate flexibility, the components produced by printed electronic processes are relatively large, the circuits are relatively simple, and the circuits are fixed in terms of circuit layout and characteristics once produced.
[0004] “Printed” batteries are often provided in order to provide power to associated printed electronic circuits. However, printed batteries have several disadvantages. Batteries employ electrolytes that make fabrication (particular with respect to sealing or encapsulation) relatively complex. Moreover, batteries lose charge over time. Batteries of sufficient charge often have a relatively large form factor, incompatible with ultra-compact or ultra-thin devices. Printed batteries may also significantly add to the cost of producing a printed electronics device.
[0005] Accordingly, there is a need for a printed electronics device with an improved power source. The power source preferably is relatively simply in design, relatively inexpensive to manufacture, may be manufactured by methods compatible with otherwise known printed electronic devices, does not suffer from loss of charge over time, and may be relatively very compact and/or thin.
SUMMARY
[0006] Accordingly, the present disclosure is directed to systems and methods for providing a card or the like employing a piezoelectric charge generator for temporarily driving a display. Printed electronic processes are utilized, and the need for a printed or supplemental battery is obviated.
[0007] According to a first aspect of the disclosure the card comprises an interactive electronic card such as business card, playing card, etc. The card may be used to exchange information (such as an address in the case of a business card) or it may be used for entertainment or advertisement purposed, etc.
[0008] A piezo-strip may be printed onto the card and an indicator may be connected thereto. The piezo-strip may also be laminated or otherwise attached to the substrate. In either case, the piezo-strip may be formed by printed electronics processes. The piezo-strip may be deflected (i.e., bent). When deflected, the piezo-strip generates a charge which may temporally drive the indicator in order to provide an interactive effect.
[0009] According to one aspect of the disclosure, the indicator is a display device, which when driven by the piezo-strip provides a printed message, image, etc. According to alternative aspects, the indicator provides audible, thermal, haptic (tactile), radio-communicative, etc. feedback. The indicator may also be formed by printed electronics processes.
[0010] The interactive indicative aspect of the card provided by the present disclosure adds value to the card since the user likely will spend more time looking at the card, may keep the card as opposed to simply throwing it away, may share the card with friends or colleagues, etc.
[0011] Thus, disclosed is an interactive card with indicator, comprising a substrate, a printed electronics indicator formed on said substrate, a first printed electronics displaceable region of piezoelectric material associated with said substrate, electrical interconnections on said substrate connecting said indicator and said first region of piezoelectric material such that displacement of said first region of piezoelectric material generates a voltage therein that is provided to said indicator in order to actuate said indicator and thereby indicate the displacement of said first region of piezoelectric material. A method of forming the interactive card with indicator is also disclosed.
[0012] The above is a summary of a number of the unique aspects, features, and advantages of the present disclosure. However, this summary is not exhaustive. Thus, these and other aspects, features, and advantages of the present disclosure will become more apparent from the following detailed description and the appended drawings, when considered in light of the claims provided herein.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] In the drawings appended hereto like reference numerals denote like elements between the various drawings. While illustrative, the drawings are not drawn to scale. In the drawings:
[0014] FIG. 1 is an illustration of a display-capable business card with piezo-strip according to an embodiment of the present disclosure.
[0015] FIG. 2 is an illustration of the display-capable business card with piezo-strip according to FIG. 1 , showing the deflection of the piezo-strip and the resulting actuation of an indicator.
[0016] FIG. 3 is a cut-away cross-section of a portion of a piezo-strip according to an embodiment of the present disclosure.
[0017] FIG. 4 is a schematic illustration of a circuit of a type which may be employed in the display-capable business card with piezo-strip shown in FIG. 1 , according to an embodiment of the present disclosure.
[0018] FIG. 5 is a photograph of a display-capable business card with piezo-strip and template over an indicator according to another embodiment of the present disclosure.
[0019] FIG. 6 is a photograph of the components of the display-capable business card with piezo-strip and template over an indicator shown in FIG. 5 .
[0020] FIG. 7 is an illustration of a two-element display and selector card with piezo-strip according to an embodiment of the present disclosure.
[0021] FIG. 8 is an illustration of a display-capable card with dual piezo-strips according to an embodiment of the present disclosure.
[0022] FIG. 9 is an illustration of an application of a display-capable card with piezo-strip as a sensor for indicating whether a door has been opened or closed, according to an embodiment of the present disclosure.
[0023] FIG. 10 is an illustration of a display-capable card in which a piezo-strip is electrically connected to a display element formed on a substrate such that the piezo-strip extends beyond the boundary of the substrate, according to an embodiment of the present disclosure.
[0024] FIG. 11 is an illustration of another application of a display-capable card with a plurality of piezo-strips and associated indicators for indicating a fluid level in a container, according to an embodiment of the present disclosure.
[0025] FIG. 12 is an illustration of fluid within a container and the display-capable card with a plurality of piezo-strips and associated indicators for indicating a fluid level of FIG. 11 disposed therein for indicating the level of the fluid within the container.
DETAILED DESCRIPTION
[0026] We initially point out that description of well-known starting materials, processing techniques, components, equipment and other well-known details are merely summarized or are omitted so as not to unnecessarily obscure the details of the present invention. Thus, where details are otherwise well known, we leave it to the application of the present invention to suggest or dictate choices relating to those details.
[0027] The piezo-charge concepts of the present disclosure are applicable to a wide variety of applications. However, in order to illustrate certain general concepts of the disclosure, a basic first embodiment comprising a display-capable business card is selected and discussed. It will be appreciated that the scope of the present disclosure is, of course, not limited to such an application. FIG. 1 illustrates such a display-capable business card 10 according to a first embodiment. Card 10 comprises a substrate 12 , which in some embodiments may be paper, card-stock, plastic, fiber-composite, laminate, or other appropriate material that may function as a business card (or alternatively as a playing card, game card, toy, sensor strip, flier, promotional advertisement, etc.) Substrate 12 may in certain embodiments have printed indicia 14 formed thereon. An indicator 16 , a piezo-strip 18 , and electrical interconnections 20 a , 20 b connecting indicator 16 and piezo-strip 18 are formed preferably by printed electronics processes on substrate 12 .
[0028] Optional printed indicia 14 may be purely informative, such as a name, address, photograph and so forth on a business card. Or, printed indicia 14 may be tied to the output of indicator 16 . For example, the printed indicia may be a question posed as part of a board game, classroom teaching lesson, etc. The correct answer may be revealed by displacement of piezo-strip 18 , causing the answer to show in indicator 16 .
[0029] Indicator 16 may be a visual indicator such as an emissive or reflective display. It may be bistable or grayscale, In other embodiments, the output of indicator 16 may be audible, thermal, haptic (tactile), radio-communicative, etc. In one embodiment, indicator 16 is an electrophoretic display. Such displays contain small, mobile particles that migrate or change orientation in the presence of an electric field. The amount of particle movement, and hence the visible contrast or change in color or tone, vary as a function of the duration and magnitude of the electric field. Such materials are compatible with printed electronic processes, thus the printed electronic processes used to form other elements on substrate 12 may also be used to form indicator 16 . While an electrophoretic display element is described above, other display types may similarly be employed. For example, liquid crystal, electrochromic, electrowetting, light emitting (e.g., organic LED), interference, electrochemical, and other forms of displays may be used. In these cases, the output of piezo-strip 18 may operate switching circuits, such as thin film transistors (not shown) to regulate the application of an appropriate driving current.
[0030] As shown in FIG. 2 , when piezo-strip 18 is deflected causing strain within the material forming a portion of piezo-strip 18 , the piezoelectric effect results in the generation of a voltage, which is at least the primary if not the sole voltage source for indicator 16 . Piezo-strip 18 is attached to substrate 12 such that it can be deflected to produce strain-induced voltage therein. Thus, in the embodiment shown, piezo-strip 18 may be separated from the balance of substrate 12 along a cut line 22 , and remain attached to substrate 12 along a common pivot edge 24 . When displaced sufficiently, or a sufficient number of times, piezo-strip 18 provides a voltage to temporarily activate indicator 16 , such as displaying an image at indicator 16 . Indicator 16 may contain a message, such as advertising, a picture, etc. or produce a sound or other “interactive” (i.e., based on the deflection of piezo-strip 18 ) effect. The result of this interactive effect is that a user is inclined to spend more time looking at card 10 , may keep card 10 as opposed to simply throwing it away, may share card 10 with friends or colleagues, etc.
[0031] FIG. 3 is a cut-away side view of a portion of card 10 and piezo-strip 18 . Initially, interconnection 20 a is formed over substrate 12 . As used herein, a piezo-strip is a body of piezoelectric material with a size (length, width, thickness) and shape appropriate for inclusion or and/or attachment to a card-like substrate. A piezo-strip may be a discrete, preformed structure attached to a substrate or applied over a region of a substrate, with or without preformed electrical contacts. Alternatively, a piezo-strip may be a region of piezoelectric material, formed by printed electronics processes or otherwise, directly on a region of a substrate. When the piezoelectric material is applied to or formed over a portion of the substrate, that portion of the substrate is referred to as a piezo-strip region of the substrate.
[0032] In one embodiment, in the region of piezo-strip 18 , a piezoelectric material 30 is deposited so that a portion of interconnection 20 a is disposed under and in electrical communication with a lower surface of piezoelectric material 30 . Piezoelectric material 30 may comprise a printed piezo-polymer such as piezoelectric polyvinylidene fluoride (PVDF), a PVDF copolymer such as PVDF-TrFE (trifluoroethylene), a printed piezo-composite, electret foam, etc. Examples of piezo-composites are silicon carbide/PVDF particulate composites, lead zirconate titanate (PZT)/polyimide particulate or fiber composites. In general, other composites combining piezoelectric particles with a piezoelectric or non-piezoelectric polymer are possible as well as piezoelectric polymers combined with non-piezoelectric particles. In one embodiment, piezoelectric material is deposited by printed electronics processes, but in other embodiments may be deposited by means other than printing, such as lamination. Alternatively, piezo-strip 18 may be formed of a ceramic piezo film which may be transfer printed onto the substrate. Thereafter, interconnection 20 b is deposited such that a portion thereof overlaps the upper surface of piezoelectric material 30 and is in electrical communication therewith.
[0033] Optionally, a proof mass (e.g., small weight) 32 may be attached to piezo-strip 18 , for example at a surface opposite that on which interconnections 20 a , 20 b , and piezoelectric material 30 are disposed, to increase the deflection force when shaking card 10 to effect deflection of piezo-strip 18 .
[0034] According to a variation of the embodiment described above, the piezo-strip may be formed separate from the substrate, then the two subsequently attached together. Adhesive, mechanical fasteners (e.g., staples), tabs, or other securing mechanism may be used to join the piezo-strip to the substrate according to this variation. Moreover, ideally, the piezomaterial layer 30 is arranged so that the neutral plane upon bending is positioned outside the layer 30 . This can be achieved for example by choosing a substrate 12 that is substantially stiffer and thicker than layers 20 a , 20 b , and 30 .
[0035] The embodiments shown in FIGS. 1 and 2 illustrate that piezo-strip 18 may be connected directly to indicator 16 such that the voltage provided by the former may temporarily activate the latter. If needed, additional circuitry may be disposed between indicator 16 and piezo-strip 18 , such as a capacitive charge storing circuit 40 shown in FIG. 4 . A rectifying diode may be patterned in series with the piezo-film in order to limit the polarity of the supply voltage to a display. A capacitor may be added to store charge and a zener diode may be used to limit the amplitude of the supply voltage. Other circuits may be employed, including resistors, or thin-film transistors to limit or control the current or voltage to the displays. In one embodiment, circuit 40 is formed on substrate 12 (e.g., FIG. 1 ) by printed electronics processes together with indicator 16 and/or piezo-strip 18 .
[0036] In the case in which indicator 16 is a visual display device, it may be patterned into a desired shape, display electrodes may be shaped to display a certain image, a template may be placed over the display surface etc., such that a desired image is presented upon deflection of piezo-strip 18 . As a further alternative, indicator 16 may comprise an area that changes color when a voltage is applied by way of deflection of piezo-strip 18 .
[0037] In the embodiment of FIGS. 1 and 2 , an electrophoretic display changes between a white and a black state depending on the voltage, and the image can be seen through a template secured over the display. This can be further illustrated with reference to the embodiment 50 illustrated in FIG. 5 , in which a template 52 is shown in place over the surface of an electrophoretic display 54 , and removed to expose the circuitry 56 and template 52 , in FIG. 6 . (the “X” shape 58 forming an opening in template 52 ). In the black state (not shown), the “X” is generally not visible, and in the white state shown in FIG. 5 it is clearly visible. The circuitry in FIG. 6 consists of inkjet-printed silver traces that connect a PVDF piezopolymer sheet 53 with and electrophoretic display 54 . The bottom electrode for the electrophoretic display and for the piezopolymer are also inkjet printed. The PVDF sheet 53 and the electrophoretic display 54 are laminated. With this concept, a message or image can be made visible or it can be concealed. It will now be appreciated that, if the card is mounted to a vibrating structure such as a car, bicycle wheel, running shoe, backpack, shopping bag, etc., an image may be displayed, or even to “flicker”, (or alternatively a sound or other indication modulated) and thereby attract attention. It may also simply indicate the presence of a certain amount of vibration, acceleration, sound or air flow.
[0038] While a single-display device is described above, devices providing two or more displays (or states) may be realized for example by card 70 illustrated in FIG. 7 . As previously described, card 70 comprises a substrate 72 , optionally having printed indicia 74 formed thereon. In the embodiment of card 70 , a two-part indicator 76 , comprising regions 76 a and 76 b , is formed on substrate 72 . A piezo-strip 78 is formed as discussed above. Electrical interconnections 80 a , 80 b are also formed on substrate 72 electrically connecting indicator 76 and piezo-strip 78 , such as by printed electronics processes.
[0039] Electrical interconnection 80 b is connected to both indicator regions 76 a , 76 b via switches 82 a , 82 b , respectively. Switches 82 a , 82 b may be temporary-connection (non-latching) switches such that when a user holds one or the other down a temporary connection is made between indicator 76 and piezo-strip 78 via that switch. When pressing switch 82 a and then actuating piezo-strip 78 , region 76 a of indicator 76 will show an image. Likewise, when switch 82 b is pressed and piezo-strip 78 is actuated, region 76 b of indicator 76 will show an image, but in this case different from the image shown when switch 82 a is pressed. Such a concept may be part of a playing card, a selection, a test card, etc. In the embodiment in which switches 82 a , 82 b are non-latching, card 70 may be reused many times and a switch must be pressed while the piezo strip is actuated.
[0040] Various discussions of printed switches, as well as actual sample switched useful in these embodiments can be found, for example, at www.vdma.org/wps/portal/Home/en/Branchen/O/OEA/?WCM_GLOBAL_CONTEXT=/vd ma/Home/en/Branchen/O/OEA/ A latching switch may be fabricated using an adhesive or tacky material between contacts in order to establish a more permanent connection. In the embodiment in which switches 82 a , 82 b are latching, card 70 may be used to more permanently record a response, such as student's answer to a test question. Other methods of temporarily or permanently selecting between displays may also be used, for example a punched hole may disconnect printed lines. Similar selection cards have been discussed which include thin-film batteries (see, e.g., www.novaled.com/downloadcenter/OE-A_Brochure2009_lowres.pdf). In each case, however, the circuit may be formed by printed electronics processes, together with the piezo-strip interactive power supply.
[0041] According to yet another embodiment shown in FIG. 8 , card 80 comprises an indicator 82 (for example a visual display, acoustic or mechanical actuator, etc.) formed on a substrate 84 . Indicator 82 is connected to a first diode 86 that rectifies the voltage provided by an actuated piezo-strip 88 . When a downward force is applied to piezo-strip 88 , it will switch the display to an indication (e.g., “white”) state, whereas an upward force on piezo-strip 88 will have no effect on the display since first rectifying diode 86 will filter out this voltage.
[0042] A second piezo-strip 90 , which bypasses first rectifying diode 86 , is formed on substrate 84 . Second piezo-strip 90 functions as a reset for indicator 82 . Piezo-strip 90 may be disposed to switch the display element to both “white” (e.g., indication) and “black” (e.g., clear) states if it is directly connected to indicator 82 (i.e., not by way of a rectifying diode). Thus, piezo-strip 90 is useful as a “reset” switch to change the display back to the “black” state. However, according to one embodiment, the function of piezo-strip 90 is limited to a reset function. In this case, piezo-strip 90 may be connected to indicator 82 via second rectifying diode 92 so that actuation of piezo-strip 90 , to initiate a reset, is limited to a single change of display state (e.g., to the clear state).
[0043] First and second rectifying diodes 86 , 92 may be transistor diodes or vertical diodes. They may be formed by printed electronics processes together with other elements of card 80 .
[0044] An optional switch 94 may be provided between indicator 82 and piezo-strip 90 in order to enable/disable the reset function of piezo-strip 90 . For example, switch 94 may consist of an electrically conductive sticker that can be removed after resetting the display (e.g., for single-use reset), or that can be removed before use of card 80 (e.g., to preclude resetting the indicator). Switch 94 may alternatively comprise a region in which the conductor can be scratched off, again after one or more uses, or before use. Switch region 94 may also simply be punched out before use by means of a hole punch or a similar device.
[0045] While the piezo-strips described above and shown in the figures have so far been a relatively small portion of the substrate on which they are formed or to which they are secured, in certain embodiments they may comprise a majority of the substrate. For example, a card may be attached to an envelope. If the envelope is bent during transport, the label will indicate this event. The fact that the piezo-strip forms a majority of the substrate, and that the substrate is on the order of the size of the envelope, means the piezo-strip will be able to sense bending at virtually any spot on the envelope.
[0046] Furthermore, while the embodiments described thus far have shown the piezo-strip as a rectangular, deflectable region, in other embodiments the piezo-strip may be in the form of a depressible button. In use, the card with a button-shaped piezo-strip may be configured such that depressing the button (one or more times) results in actuation of a connected indicator, as previously described. Thus, many actual shapes and configurations of the piezo-strip are contemplated and disclosed herein.
[0047] In another embodiment, a card of a type disclosed herein may function as a motion sensor. If a proof mass is optionally attached to a piezo-strip, motion exceeding a desired threshold (such as a drop) will deflect that piezo-strip and actuate the display. The flexibility of the piezo-strip, the proof mass, the display characteristics, the piezoelectric material employed etc. all may be tailored to provide a desired sensitivity of such a motion sensor. Furthermore, a card of the type disclosed herein may also serve as a vibration sensor in which a vibration force on a piezo-strip slowly charges up the indicator (e.g., an electrophoretic display), a storage circuit connected to the indicator, etc. Other forces such as air or fluid pressure may also cause an actuation of a piezo-strip in a card of a type disclosed herein.
[0048] Still further, a card of the type described herein may also be used to indicate whether a door, lid, etc., has been opened, closed, etc. For example, with reference to FIG. 9 , a card 90 may be secured to a door 92 . Card 90 has a piezo-strip 94 that may be secured to door frame 96 (or alternatively wall, door jamb, trim, hinge, etc.). Piezo-strip 94 may be deflected when opening or closing door 92 , and so may actuate an indicator 98 , for example to display a message. In such embodiments, and others described herein, the piezo strip may extend beyond the peripheral dimensions of the display carrying portion of substrate 100 , as illustrate in FIG. 10 .
[0049] According to still another application of a piezo-charge device according to the present disclosure, several piezo-strips may be formed on or attached to a single substrate to form a level or flow sensor for, for example, fluids. With reference to FIG. 11 , card 110 comprises a substrate 112 on which is formed a plurality of indicators 114 a , 114 b , 114 c . A plurality of piezo-strips 116 a , 116 b , 116 c . are formed on or attached to substrate 112 as previously described, and electrically interconnected to a respective indicator 114 a , 114 b , 114 c . Each piezo-strip 116 a , 116 b , 116 c . may be combined with a diode (not shown) to rectify the voltage, as previously described for example with reference to FIG. 8 . Optionally, a reset piezo-strip 118 may be provided, as discussed above.
[0050] Card 110 can be folded over at line 118 , and draped over the rim of a vessel 120 containing liquid 122 . Piezo-strips 116 a , 116 b , 116 c should therefore be formed of material or coated with material permitting them to be immersed in liquid. Any of a wide variety of waterproof or chemical proof coatings may be used provided they do not restrict the displacement of piezo-strips 116 a , 116 b , 116 c . Optionally, the entirety of card 110 may be immersible in liquid. The present embodiment is advantageous for use with an opaque container, where viewing the liquid level is difficult. When agitated, liquid 122 causes displacement of piezo-strips 116 a , 116 b , which are immersed in the liquid. Piezo-strip 116 c is not displaced (or at least displaced to a much lesser extent than piezo-strips 116 a , 116 b ) due to the fact that it is not within liquid 122 . The displacement of piezo-strips 116 a , 116 b results in a change of state (e.g., black to white) of indicators 114 a , 114 b , while indicator 114 c does not change state (e.g., remains black). Thus, motion of liquid 122 will result in an indication of the level of the fluid within container 120 .
[0051] It will now be appreciated that a variety of different embodiments and variations thereof have been disclosed which illustrate the scope of the present disclosure. However, several further general statements should be made. First, it should be understood that when a first layer is referred to as being “on” or “over” a second layer or substrate, it can be directly on the second layer or substrate, or on an intervening layer or layers may be between the first layer and second layer or substrate. Further, when a first layer is referred to as being “on” or “over” a second layer or substrate, the first layer may cover the entire second layer or substrate or a portion of the second layer or substrate. Still further, additional layers such as protective layers may be formed over the described layers.
[0052] No limitation in the description of the present disclosure or the claims following can or should be read as exclusive or absolute. The limitations of the claims are intended to define the boundaries of the present disclosure, up to and including those limitations. To further highlight this, the term “substantially” may occasionally be used herein in association with a claim limitation (although consideration for variations and imperfections is not restricted to only those limitations used with that term). While as difficult to precisely define as the limitations of the present disclosure themselves, we intend that this term be interpreted as “to a large extent”, “as nearly as practicable”, “within technical limitations”, and the like.
[0053] Furthermore, while a plurality of preferred exemplary embodiments have been presented in the foregoing detailed description, it should be understood that a vast number of variations exist, and these preferred exemplary embodiments are merely representative examples, and are not intended to limit the scope, applicability or configuration of the disclosure in any way. For example while each of the embodiments discussed above has contemplated a piezo-strip which is partly separated from the substrate, it is within the scope of the present disclosure to provide a piezoelectric material over a fully-attached portion of the substrate, which may be displaced and generate the desired voltage.
[0054] Various of the above-disclosed and other features and functions, or alternative thereof, may be desirably combined into many other different systems or applications. Various presently unforeseen or unanticipated alternatives, modifications variations, or improvements therein or thereon may be subsequently made by those skilled in the art which are also intended to be encompassed by the claims, below. And the present disclosure may find use in any of a wide variety of applications such as, but not limited to, business cards, greeting cards and novelty items, toys and games, advertising and promotions, testing and education, sensors, etc.
[0055] Therefore, the foregoing description provides those of ordinary skill in the art with a convenient guide for implementation of the disclosure, and contemplates that various changes in the functions and arrangements of the described embodiments may be made without departing from the spirit and scope of the disclosure defined by the claims thereto. | An interactive card or the like employs a piezoelectric charge generator (piezo-strip) for temporarily driving an indicator. The piezo-strip may be displaced (bent) in order to generate charge to drive the indicator. Printed electronic processes are utilized to produce the indicator and/or the piezoelectric charge generator The need for a printed battery or supplemental power source is obviated. The card may carry printed indicia which corresponds to the states of the indicator (e.g., indication of a test answer selection). Multiple display elements and selector switches may provide multiple indicator states. Multiple piezo-strips may provide a selection function as well as a rest function. Applications include business cards, greeting cards and novelty items, toys and games, advertising and promotions, testing and education, sensors, and so forth. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a card containing a component and to a micromodule adapted to a card of this type. The invention finds an application in the fields of production and utilization of electronic control cards or electronic cash cards.
2. Description of the Prior Art
In the prior art, electronic payment or control cards already exist in a credit-card format. In known designs, electronic components of the memory-microcomputer type are mounted in cards of this type and serve to relieve terminals of part of the "intelligent" work. In the different professional fields, a distinction is made between manufacture of the card itself and manufacture of the component itself or association of both components considered together. The micromodule which contains a component integrated in a card is usually produced by an integrated circuit manufacturer. The production methods employed are derived directly from production lines for the manufacture of integrated semiconductor circuit packages.
The present invention proposes a novel micro-module and a novel card which is specially intended to permit the use of conventional integrated-circuit production lines for the manufacture of cards of this type. The invention offers a further advantage in that the integrated semiconductor circuit can readily be changed on the card. It is thus possible to recycle the cards at the end of a period of use.
SUMMARY OF THE INVENTION
The present invention is in fact concerned with a card containing a semiconductor component of the type in which contact pads are placed at predetermined points defined by a standard on a substrate having a credit-card format. The card is provided with at least one recess in one face which carries the contact pads, the sides of the recess being adapted to carry transfer contacts for establishing electric connections between the contact pads and the terminals of a micromodule which is plugged into the recess.
The invention is also concerned with a micro-module specially adapted to a CCC (chip carrying card) card in accordance with the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sectional diagram of a micro-module in accordance with the invention.
FIG. 2 is a partial view of a CCC card in accordance with the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 is a partial view of a micromodule adapted to the present invention, in which an integrated circuit 1 is fabricated from a semiconductor silicon chip. Connections formed by studs 2, 4 of filler metal are particularly well-suited to a continuous connection process. The semiconductor circuit is placed on a substrate 6 which will constitute part of a complete resin package 8. Metallic films in the form of beam leads such as those designated by the references 3 and 5 are placed automatically above the series of studs 2, 4. Each beam lead is soldered to a corresponding connection stud. The remainder of the package is then formed by encapsulation of the assembly. Finally, each beam lead 3, 5 is cut so as to be separated from the connecting tape. This method of establishing connections is known as the TAB (tape-automatic-bonding) process.
In accordance with the present invention, a side contact is made between the micromodule and the CCC card in which the micromodule is to be mounted. In order to establish a connection of this type, the invention proposes to bend each beam lead laterally in the downward direction against the sides of the chip carrier package. In the example of construction shown in FIG. 1, the completed bending operation is represented solely by the dashed line 7. In an alternative form of construction which constitutes another distinctive feature of the invention, the downwardly-bent beam leads 7 are guided and maintained by means 9 of recesses formed by molding in the chip carrier package. Thus the beam leads are intended to engage by snap action within said recesses in such a manner as to remain continuously in the desired position.
FIG. 2 illustrates a CCC card for receiving a micromodule in accordance with FIG. 1. The card 10 has a recess 11 in which the micromodule is intended to engage. Two rows of terminal connections or contact pads 12, 13 are located on each side of the recess 11. Each connection such as the pad 15 is positioned in accordance with a standard scheme of connections which is pre-established for cards of the CCC type. The connections on the card must necessarily comply with dimensions designated in the figure by the references 17-19. These dimensions are mainly the distance from center-line of one row 12 or 13 to one edge 17, the spacing of two rows 18 and the spacing or pitch 19 of two connections of one row. Since these dimensions do not correspond to standard dimensions of known connections as established by integrated semiconductor circuit standards, transfer connections are provided in order to adjust the side contacts of the micromodule to the contacts such as the contact pad 15 on the card. To this end, metallic strips are so arranged as to connect each contact pad such as the pad 15 to a side contact which is suitably arranged within the recess 11. These metallic strips can be obtained by different methods. In particular, strips of conductive metal can be adhesively bonded to the card surface. In another method of fabrication, the connections are made by hot-state pressing of conductive metal strips on the plastic card. In a further method of fabrication, the connections are deposited on the card by screen process. Finally, in yet another method of fabrication, the connections are deposited on the card by sputtering of metal in a vacuum.
After fabrication of the card, it is possible to deposit a semiconductor circuit in a micromodule such as the micromodule of FIG. 1 within the recess 11. The micromodule is installed within the recess and held in position therein by the elasticity of the side contacts such as the contact 7. In one embodiment which is illustrated by way of example in FIG. 2, snap-engagement means 14 are provided within the recess and adapted to cooperate with corresponding means on the micromodule or chip carrier package 8. In accordance with this distinctive feature, the snap-action engagement produced at the time of insertion of the micromodule in the card ensures permanent assembly during all normal handling operations performed by users.
The advantage offered by the present invention lies in the fact that it finds a practical application in production lines for the manufacture of standard integrated circuits. Another advantage is that the invention makes a distinction between on the one hand the particular problems of plug-in connection systems specifically in relation to the use of electronic cards and on the other hand the electronic problems presented by integrated circuits. By means of the invention, the integrated circuit which is the central core of the card can thus be made detachable. The card can therefore be reused several times for a number of different applications according to the micromodule which is employed. | A card having contact pads disposed in rows and spaced in accordance with electronic card standards is provided with a recess for snap-action engagement of a pluggable micromodule having side contacts and containing the core component of the card. The micromodule is connected to the rows of contact pads by means of transfer contacts formed by metallic strips and side contacts within the card recess. | 7 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of priority pursuant to 35 U.S.C .§119 and the Paris Convention, to the Polish Patent Application No. P 398697 filed Apr. 2, 2012, the contents of the application is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] The subject of the invention is a method for processing of heat energy absorbed from the environment and a unit for processing of heat energy absorbed from the environment, used for the supply of energy load points, especially electric load points, especially in places with large and frequent changes of environment temperature.
[0003] The subject matter of the invention is an improvement to known methods of obtaining of energy, also electric energy, from natural sources of energy, and methods used for the transformation of natural energy in useful energy.
[0004] Humanity has, for a long time, used wind energy, transformed in various devices into driving energy for load points, such as mills and other driving force load devices. With the development of technology and the invention of electrical current, the wind energy was used to drive power generators.
[0005] The energy of water was also used, with the water flow energy driving various types of devices transforming this energy to useful energy, supplying various types of load points, and also driving electric power generators.
[0006] Solar power was also used, transformed in devices into useful energy for heating or supplying of other electric current load points.
[0007] All the listed sources of natural energy may be used only when this energy is present in a limited location, such as water-power plants, or at a limited time, like solar batteries or wind-power plants, which reduces the usefulness of its usage.
[0008] The solution used in the description GB 984268 has a filament located in an air bellows, in which it heats the air, which as a result of thermal expansion creates increased pressure, enabling the lengthening of the bellows and applying force to a moving element of the end of the bellows.
[0009] In the solution in the JP 61089975 patent, the piezoelectric phenomenon was used to move the needle powering the piston of the load point.
[0010] The system described in U.S. Pat. No. 5,822,989 presents a friction brake switch, in which the element applying pressure to disks through a bearing is a set of sockets with polymers, expanding through the phenomenon of thermal expansion.
[0011] A solution is known, presented in Polish Patent description no 210333 in which the method of transforming of heat energy from the environment, the essence of which is having an element with a high thermal expansion coefficient is connected mechanically with a moving element of an energy accumulator, which is then connected to an actuating element, which is then connected to the load point.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is a flowchart of a one embodiment of the invention;
[0013] FIG. 2 is a flowchart of another embodiment of the invention;
[0014] FIG. 3 is a diagram of a unit for one embodiment of the invention; and
[0015] FIG. 4 is a diagram of a unit for another embodiment of the invention.
SUMMARY OF THE INVENTION
[0016] This method is realised in the unit, which consists of an element with a high thermal expansion coefficient, connected mechanically with a moving element of an energy accumulator, which is then connected to an actuating element, which is connected to the load point.
[0017] The goal of the invention is to eliminate the abovementioned defects and problems and to propose a method which enables the transformation of heat energy from the surrounding to another form of energy and a unit for the implementation of this method.
DETAILED DESCRIPTION
[0018] The essence of the invention, which is a method of transforming of heat energy, absorbed from the environment, having an element with a high thermal expansion coefficient, connected mechanically on at least one end with a moving element of an energy accumulator, which is then connected to an actuating element, which is then connected to the load point, consists of an energy accumulator connecting to an actuating element through an energy level controller.
[0019] It is advantageous, when a mechanical controller is used as an energy level controller.
[0020] It is also advantageous, when a flow choke with outflow control is used as an energy level controller.
[0021] It is also advantageous, when a bimetallic system is used as an energy level controller.
[0022] It is also advantageous, when a multi-joint flat system is used as an energy level controller.
[0023] This method is used in an unit for the transforming of heat energy, absorbed from the environment, the essence of which consists of having an element with a high thermal expansion coefficient, connected mechanically on at least one end with a moving element of an energy accumulator, which is then connected to an actuating element, wherein between the energy accumulator and the actuating element an energy level controller is placed.
[0024] It is advantageous, when the energy level controller is a mechanical controller.
[0025] It is also advantageous, when the energy level controller is a flow choke with outflow control.
[0026] It is also advantageous, when the energy level controller is an electric controller.
[0027] It is also advantageous, when the energy level controller is a bimetallic system.
[0028] It is also advantageous, when the energy level controller is a multi joint flat system.
[0029] The use of the solution presented in the invention enables the following technical and utility effects:
[0030] the ability to use heat energy drawn from the environment when the environment temperature changes and to use it into technically usable energy,
[0031] the ability to control the amount of energy transferred to the load point,
[0032] the ability to supply energy load points regardless of the time of the day and year,
[0033] maintenance-free device,
[0034] the ability to use to use in any time and place regardless of the presence of sun, wind and flowing water stream and to supply energy to any load point.
[0035] The subject of the invention in a sample implementation was described in below examples and was shown on the drawing, where on FIG. 1 a flowchart with a one-sided power draw is presented, on FIG. 2 a flowchart with a two-sided power draw is presented, on FIG. 3 a diagram of the unit for transforming the heat energy with an element with lengthwise thermal expansion direction is presented, and on FIG. 4 with an element with volumetric thermal expansion is presented.
[0036] The unit in one of the implementation versions is formed of an element 1 with a large of lengthwise thermal expansion coefficient, which is advantageously a rod. This rod is connected mechanically with a moving element of the energy accumulator 2 , which is then connected by an energy level controller 3 with an actuating element 4 , to which an energy load point 5 is connected. The energy accumulator 2 in one of non-limiting versions of implementation is a closed fluid tank, in which a sliding piston 6 is placed, which is the moving element of the energy accumulator 2 . Energy accumulator 2 within the closed space wall has an energy level controller 3 , which is a variable flow nozzle with an outlet in the turbine blades zone, forming the actuating element 4 . Turbine 4 is mechanically connected with the alternator 7 , which is connected with an energy load point 5 , which is advantageously a battery for powering of other electric load points, not shown on the drawing.
[0037] In other implementation version the turbine 4 is connected with an alternator 7 through a mechanical transmission.
[0038] In another implementation version the element 1 has pistons 6 of energy accumulators 2 mounted on both ends, which, as in the implementations above are connected by a mechanical energy level controller 3 with actuating elements 4 and energy load points 5 .
[0039] Depending on the version of implementation, the energy level controller is a a mechanical flow choke, with outflow control, electric controller, bimetallic system, or a multi-joint flat system
[0040] There are versions, presented on FIG. 4 , in which element 1 is a high thermal expansion coefficient medium, advantageously gas, fluid, mercury or other medium. This medium is closed in a container 8 , having a cylinder 9 with a piston 10 . The piston 10 is connected with a sliding element of an energy accumulator 2 , which through an electric energy level controller 3 is connected to an actuating element 4 .
[0041] In a next version of implementation, not shown on the drawing, the energy accumulator 2 is a set of springs, of which one is compressed and another one is stretched. The springs are connected with the end of the element 1 and with the known element for transforming the potential energy of the spring to kinetic energy, which sends this energy to the impeller of the generator 8 .
[0042] Change of the environment temperature causes the change of the length of the element 1 and movement of the piston 6 . In another implementation the change of the environment temperature causes the increase of the volume of the medium 1 in the container 8 and the movement of piston 10 in the cylinder 9 , and thus the movement of the piston of the energy accumulator 2 . In one of the versions of the implementation the fluid contained in the energy accumulator 2 will be injected by a nozzle 3 onto the blades of the turbine 4 . Turbine 4 drives the alternator 7 directly or through a mechanical transmission. The current created in the alternator 7 powers the energy load point 5 .
[0043] In another version of the implementation the change of length of the element 1 causes the movement of two pistons 5 in energy accumulators 2 and causes the turbines 3 to drive two alternators 7 .
[0044] To increase the clarity of the description, we have resigned to present the solution of the energy amount control systems 3 depending on the direction of the temperature gradient changes.
[0045] It is to be understood that the above description is intended to be illustrative, and not restrictive. For example, the above-described embodiments (and/or aspects thereof) may be used in combination with each other. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from its scope. While the dimensions and types of materials described herein are intended to define the parameters of the invention, they are by no means limiting, but are instead exemplary embodiments. Many other embodiments will be apparent to those of skill in the art upon reviewing the above description. The scope of the invention should, therefore, be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. In the appended claims, the terms “including” and “in which” are used as the plain-English equivalents of the terms “comprising” and “wherein.” Moreover, in the following claims, the terms “first,” “second,” and “third,” are used merely as labels, and are not intended to impose numerical requirements on their objects. Further, the limitations of the following claims are not written in means-plus-function format and are not intended to be interpreted based on 35 U.S.C. §112, sixth paragraph, unless and until such claim limitations expressly use the phrase “means for” followed by a statement of function void of further structure. | The subject of the invention is a method for processing of heat energy absorbed from the environment and a unit for processing of heat energy absorbed from the environment, used for the supply of energy load points, especially electric load points, especially in places with large and frequent changes of environment temperature. The system uses an energy accumulator, which is connected to an actuating element through an energy level controller. This method is implemented in a stand-alone unit, wherein an energy level controller is placed between the energy accumulator and the actuating element. | 5 |
FIELD OF THE INVENTION
[0001] The present invention relates generally to display systems and more particularly to establishing a preferred display format in an extended video display for requesting the preferred format from a video source.
BACKGROUND
[0002] Many modem video display systems can display video in more than one format, e.g. high definition or standard definition, using more than one aspect ratio. When this is the case, the source of video interprets this information and sends the display a particular format, depending on how the source has interpreted the display characteristics. The restriction on present systems is that the decision by the source regarding the format chosen to display the video data is automatic and may not necessarily be the one desired by the user. The user is thereby limited to the choice made by the source itself. This presents a problem when using current technology because, with high definition displays becoming more readily accessible, the user may wish to request that the source send video in a user-selected format instead of one chosen by the source for its own convenience. Furthermore, current processes to display certain data could undesirably include multiple format changes which inevitably introduce some features that impair picture quality of the data on display.
[0003] With more specificity using a non-limiting example, in an enhanced extended display identification database (E-EDID) device, formats that are supported by the device are listed and one of the listed formats can be marked as being the native timing of the display.
[0004] In general, the source device is required to read the contents of the video device over a specified channel. The source then interprets this data. The source then outputs a format, but as discussed above the source is not required to output a particular format. It is only required to output a format that is within the capabilities of the display device, as described in the EDID data. There is no requirement that the source device output the content in the format which matches the user's preferred timing of the display.
SUMMARY OF THE INVENTION
[0005] A method for establishing what format video is received from a source of video includes dynamically establishing at least one parameter that is associated with a user-preferred format in a memory of a video display system. The parameter is sent to the source to cause the source to send video to the display system in the desired format.
[0006] The parameter may be established in an extended display information data (EDID) electrically erasable programmable read-only memory (EEPROM) associated with the video display system. The parameter may be timing, scan lines, or aspect ratio, and can be communicated to the source in a plug-and-play operation.
[0007] In some embodiments the method may include allowing a user to select one parameter from a group of parameters stored in the EEPROM, with the EEPROM being altered as necessary to reflect the user selection. In other embodiments the method may include allowing a user to select one parameter from a group of parameters, with the EEPROM being dynamically altered as necessary to contain only the parameter selected by the user. In this latter embodiment a checksum associated with the EDID in the EEPROM is dynamically established to reflect the parameter selected by the user.
[0008] In another aspect, a video display system includes a processor and a format information storage apparatus. The processor presents to a user a visual display and then permits the user to use the visual display to define a preferred video format. The processor programs the format information storage apparatus such that the format information storage apparatus can indicate to a source of video the preferred video format. Consequently, the source sends video to the display system formatted in the preferred way.
[0009] In yet another aspect, a video display source includes a processor that receives information from a video display system. The information includes a parameter which is established in response to a user selecting a preferred display format. The processor of the video display source causes the source to send video data to the video display system in the preferred display format in response to the parameter.
[0010] The details of the present invention, both as to its structure and operation, can best be understood in reference to the accompanying drawings, in which like reference numerals refer to like parts, and in which:
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is block diagram of the present system;
[0012] FIG. 2 is a flow chart of the general logic;
[0013] FIG. 3 is a flow chart of one implementation of the present logic; and
[0014] FIG. 4 is a flow chart of another implementation of the present logic.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0015] Referring initially to FIG. 1 , a system is shown, generally designated 10 , that includes a video source 12 and a digital display system 14 , sometimes colloquially referred to as a “sink”. As indicated in FIG. 1 , the video source 12 communicates video data to the display system 14 for display of the video. Also, the source 12 can access display information at the display system 14 for purposes to be shortly disclosed.
[0016] As shown, the video source 12 includes a processor 16 that can access a program memory 18 to function in accordance with present principles. The program memory 18 can be any appropriate memory including, without limitation, disk and/or solid state memory.
[0017] As also shown in FIG. 1 , the display system 14 may include a processor 20 that can access a program memory 22 to function in accordance with present principles. The program memory 22 can be any appropriate memory including, without limitation, disk and/or solid state memory.
[0018] In addition to or in lieu of the program memory 22 , the display system 14 may access a format information storage apparatus, such as but not limited to an extended display information data (EDID) electrically erasable programmable read-only memory (EEPROM) 24 . In accordance with present principles, the EEPROM 24 is dynamically changeable by a user to indicate a user-preferred format and if desired other display data for communication thereof to the video source 12 . The user-definable preferred video format may be established by appropriately manipulating a remote control device 26 , such as a TV remote control, in response to a format selection prompt that may be presented, along with video, on a monitor or display device 28 .
[0019] In accordance with present principles, the video source 12 may be, without limitation, a DVD player, a satellite receiver, a set-top box, and so on. On the other hand, the display system 14 may be, without limitation, a television display system including a cathode ray tube (CRT) display, a liquid crystal display (LCD) or other flat-panel display, etc. The display system 14 is capable of displaying video in a user-selectable one of plural formats on the display device 28 . These formats include various timings and related aspect ratios, e. and without limitation, 480 scans lines either progressive scan (480p) or interlaced output scan (480i), and 720 lines progressive scan, and 1,080 lines interlaced output scans, in conventional 16:9 aspect ratios or in high definition (HD) 4:3 aspect ratios. As is well known in the art, these format parameters are associated with respective “timings”, i.e., the scan timing depends on, among other things, the number of scan lines and the aspect ratio.
[0020] Now referring to FIG. 2 , the general logic for dynamically establishing the display format is shown. Starting at block 30 , the logic dynamically establishes the preferred display format at the display system. In one non-limiting embodiment, this may be done by allowing the user to appropriately enter information representing the user-preferred display format into the E-EDID data, e.g., information representing the user's preferred format in terms of timing and/or scan lines and/or aspect ratio. Upon plug and play connection, e.g. hot plug detect, a DO loop occurs at block 32 , moving the logic to block 34 . At block 34 , the display device requests the video source to send data in the preferred format to be shown to the user. The preferred format may be established based on one of two of the specific implementation processes outlined in FIGS. 3 and 4 .
[0021] In one exemplary non-limiting implementation, the logic at block 30 in FIG. 2 may be executed by setting a flag in block 0 of the EDID data which points to the first descriptor block in block 1 . The first descriptor block can have a so-called “CEA” header having a table of short video format descriptors, and a bit in the descriptor that is preferred by the user may be set in accordance with the logic at block 30 of FIG. 2 to indicate that it is the preferred format.
[0022] FIG. 3 shows one specific implementation for allowing the user to define a preferred video format. At block 36 , the user manipulates the button or menu entry on the video display (using the remote control 26 shown in FIG. 1 or other control device). Available format timing descriptions then cycle on the display screen as the “preferred” format as indicated at block 38 . In one non-limiting implementation, the “preferred” format is reflected in block 0 of the E-EDID data. At block 40 the user selects, e.g., by pushing the “enter” button on the remote control device 26 , the format timing preferred by the user. Block 42 shows that the EEPROM configurations are changed as necessary to reflect the preferred format requested. Video sent from the video source to the video display will then be in the user-specified format. In the particular implementation shown in FIG. 3 , the EEPROM EDID data contains all the possible formats used by the display device, and identifies, for subsequent access by the source, the preferred format; accordingly, since all possible formats are always present in the EDID data in the EEPROM, the check sum of the EDID does not change.
[0023] An example of how to implement this method would be for the user to decide which format is desired before the beginning of the data display. This can be done upon display system startup at a formatting screen presented to the user before the “normal” viewing screen appears, where all the formatting options are presented to the user. The format chosen by the user'is then entered into the EEPROM for subsequent access by a video source in determining which video format to use.
[0024] A second method of specific implementation for establishing a preferred video format is shown in FIG. 4 . Commencing at block 44 , the user manipulates a button to select a menu entry on the display using, e.g., a remote control device to display different format options/choices. As the user cycles through the format choices, the EDID in the EEPROM is modified to list only the choice of format that is currently displayed on the video display screen, as indicated in block 46 . As indicated at block 48 , the check sum of the EDID is modified as necessary to reflect the user's format choice, since at the end of the selection process EDID data representing some non-preferred formats is eliminated from the EEPROM. In other words, this method outlines a procedure for “flipping” through the different format choices until one that is most acceptable to the user is displayed on the screen and exclusively entered into the EEPROM EDID data.
[0025] While the particular SYSTEM AND METHOD FOR DYNAMICALLY ESTABLISHING EXTENDED DISPLAY IDENTIFICATION DATA as herein shown and described in detail is fully capable of attaining the above-described objects of the invention, it is to be understood that it is the presently preferred embodiment of the present invention and is thus representative of the subject matter which is broadly contemplated by the present invention, that the scope of the present invention fully encompasses other embodiments which may become obvious to those skilled in the art, and that the scope of the present invention is accordingly to be limited by nothing other than the appended claims, in which reference to an element in the singular is not intended to mean “one and only one” unless explicitly so stated, but rather “one or more”. It is not necessary for a device or method to address each and every problem sought to be solved by the present invention, for it to be encompassed by the present claims. Furthermore, no element, component, or method step in the present disclosure is intended to be dedicated to the public regardless of whether the element, component, or method step is explicitly recited in the claims. Absent express definitions herein, claim terms are to be given all ordinary and accustomed meanings that are not irreconcilable with the present specification and file history. | Preferred format parameters including timing that is contained in an extended display information data (EDID) EEPROM in a digital video display system can be dynamically established by a user. In this way, when the video display system engages a source of video in a “plug and play” context, instead of communicating to the source what formats are supported and then accepting a format selected by the source, the preferred format is sent from the EEPROM to the source so that the video display system receives video from the source in the user-desired format. | 6 |
CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This application claims the benefit of German patent application 10211817.5 filed Mar. 16, 2002, herein incorporated by reference.
FIELD OF THE INVENTION
[0002] The present invention relates generally to spinning devices, and more particularly to spinning devices for open-end rotor spinning machines.
BACKGROUND OF THE INVENTION
[0003] Spinning devices for open-end rotor spinning machines are known.
[0004] For example, German Patent Publication DE 197 08 944 A1 discloses an open-end spinning machine with a spinning rotor, having a rotor shaft supported on a support disk bearing and a rotor cup that rotates in a rotor housing, that can be closed by means of a cover element and can be charged with a vacuum.
[0005] German Patent Publication DE 39 42 402 C2 discloses a similar spinning device. With this known spinning device, the rotor shaft of the rotor is also rotatably seated in two wedge gaps of a support disk bearing, and a tangential belt extending over the length of the machine acts on it. In this case the tangential belt simultaneously drives all spinning rotors of a side of the machine.
[0006] On the side opposite the wedge gaps, an expander roller is assigned to each rotor shaft that loads the tangential belt in the direction of the rotor shaft. The expander roller is seated, freely rotatable on a shaft of a two-armed expander roller holder that is pivotable around an axis extending parallel with respect to the axis of rotation of the expander roller and is loaded by means of a spring element. Moreover, the expander roller holder is connected via a pressure lever system with an actuating lever that when acted upon during the run-up of the spinning rotor results in an increase of the pressure force of the tangential belt against the respective rotor shaft.
[0007] This known spinning device has a pincer-like rotor brake, the ends of whose pincer arms are equipped with brake linings. The pincer arms are maintained in the opened state by a hoop spring or the like and can be applied to the rotor shaft by means of a brake gear.
[0008] Here, the rotor brake and the expander roller are connected via a common actuating mechanism in such a way that when the spinning device is opened, i.e. when the cover element is pivoted away from the rotor housing, the expander roller is automatically lifted off the tangential belt against the force of the spring element resting on it, and the rotor brake is closed. In this way the spinning rotor is dependably braked to a stop.
[0009] The above described spinning devices have been in actual use and have been employed in large numbers in the textile industry for quite a while.
[0010] However, under rare exceptional conditions, for example in the case of a defect in the tangential belt or unbalanced rotation of a spinning rotor, it can happen that the spinning device is charged with internal forces which, for example, results in the expander roller suddenly jumping up. In rare cases these internal forces can lead to the spinning device being opened before the spinning rotor has stopped which is not without danger for the operators.
SUMMARY OF THE INVENTION
[0011] It is accordingly an object of the present invention to provide a spinning device in which the unintentional opening of the spinning device is dependably prevented under any circumstances. This object is addressed by providing a spinning device comprising a spinning box housing fixable on a base frame of a textile machine and supporting a rotor housing; a spinning rotor having a spinning cup on a rotor shaft supported in bearing nips of a support disk bearing for rotation of the rotor during spinning at a high number of revolutions in the rotor housing, a cover element for closing and opening the rotor housing, an arrangement for charging the rotor housing with a vacuum; a traveling belt acting tangentially on the rotor shaft, a rotor brake having a brake gear; a pivotable expander roller moveable within a maximum pivot angle via a pressure lever system connected to the brake gear of the rotor brake between an operative position when the spinning box is closed in an inoperative position wherein the expander roller is automatically lifted off the tangential belt and the rotor brake is applied to the rotor shaft when the spinning box is opened, a brake and locking lever having a locking recess in contact with an arresting roller arranged on the cover element; and an arrangement in the pressure lever system for absorbing shock-like forces acting on the expander roller and for preventing the forces from being transmitted to the brake and locking lever.
[0012] The spinning device of the present invention has the particular advantage that its cover element is positively locked. This lock can only be opened from the outside and, after opening, it is assured that the spinning rotor no longer rotates.
[0013] Thus, an advantage of the present invention is that it is assured that the spinning device is not inadvertently opened by internal forces, even in case of possible malfunctions.
[0014] In a preferred embodiment of the present invention, a device is provided in the area of a cross arm of the spinning box housing which makes it possible to preset the maximum pivot angle of the expander roller. In case of a malfunction, such a travel limiting device prevents the expander roller from being flipped upward past a predetermined amount and, in the course of this movement, from also lifting the brake and locking lever positively fixing the spinning device in place, out of its locked position.
[0015] Furthermore, such a travel limiting device assures that a flipped-up expander roller cannot damage either the spinning device itself or adjacent components of the spinning device.
[0016] A travel limiting device can be simply produced as follows. An elongated hole recess arranged in a cross arm of the spinning box housing is placed and dimensioned in such a way that the freedom of movement of the lifting hoop for actuating the expander roller and guided in the elongated hole recess is minimized. Since the lifting hoop is connected to the pivotably seated expander roller holder, it is relatively simple to preset the pivot angle of the expander roller.
[0017] However, in an advantageous manner, a limitation of the pivot angle can also be achieved. For example, a special detent element is positioned in the area of the elongated hole recess. Such a detent element is seated, for example, on the connecting shaft of the lifting hoop/expander roller holder and extends with a guide pin into the elongated hole recess. The pivot angle of the expander roller can also be effectively limited by such a detent element.
[0018] Another advantageous embodiment of the present invention is where a lifting hoop of the expander roller, connected via a connecting means to a pressure increasing lever, is connected via an arrangement having an elongated hole guide with the brake and locking lever such that the arrangement and length of the elongated hole guide arranged on the brake and locking lever is selected to be such that no forces are transmitted to the brake and locking lever from the expander roller. This embodiment makes, on the one hand, a dependable triggering of the expander roller possible in case of need and, on the other hand, assures that the spinning device cannot be opened by internal forces.
[0019] In the course of the acceleration of the spinning rotor during the resumption of spinning by the spinning device it is possible, on the one hand, to increase the pressure force of the tangential belt against the rotor shaft by means of the pressure increasing lever but, on the other hand, for example in case of damage to the rotor or tangential belt, the described arrangement prevents the unlocking of the spinning device and its opening while the rotor is running.
[0020] Another embodiment of the present invention includes an arrangement that has a strip arranged on the back of the brake and locking lever and resting on the connecting means. Still yet another embodiment of the present invention includes an arrangement inserted into the lifting hoop allowing pressure to be applied to the expander roller via the pressure increasing lever, but compensating in an opposite direction a transmission at least of shock-like introduced forces to the brake and locking lever.
[0021] As an alternative to the above embodiments that relate to the linkage area of the pressure increasing lever/brake and locking lever/lifting hoop, the present invention also encompasses an embodiment in which a device absorbs shocks being passed on to the associated lifting hoop, for example, when an expander roller is flipped up.
[0022] Such an arrangement at least absorbs shock-like occurring forces and in this way prevents their being passed on to the brake and locking lever.
[0023] In yet another embodiment of the present invention, the lifting hoop is preferably embodied in two parts, and the two hoop elements are connected by means of a non-positively operating coupling device.
[0024] In case of shock-like occurring forces, the lifting hoop is shortened without it being possible in this case to transmit forces to the brake and locking lever.
[0025] The coupling device is comprised of, for example, a plastic element having spring-loaded arresting tongues. The arresting tongues act together with corresponding sliding faces on one of the two hoop elements.
[0026] By means of the shape and arrangement of the arresting tongues, as well as of the associated sliding faces on the hoop element, it is possible here to determine at which size of a shock a relative movement of the hoop element occurs as well as to assure that the expander roller can be acted upon by the pressure increasing lever.
[0027] A further embodiment of the present invention provides that an additional lever is fixed on the brake and locking lever that has a catch for the positive reception of the locking roller arranged on the cover element. Such an embodiment also represents a dependable and simple arrestment of the cover element in its locked position.
[0028] Further details of the invention can be gathered from a non-limiting exemplary embodiment presented in the following description with reference made to the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0029] [0029]FIG. 1 is a lateral view of an open-end rotor spinning device, wherein an arrangement has been inserted into the pressure lever system for the expander roller which prevents the transmission of forces via a lifting hoop to a brake and locking lever.
[0030] [0030]FIG. 1A, is an enlarged view of the arrangement inserted into the pressure lever system.
[0031] [0031]FIG. 1B is an enlarged view of the arrangement inserted into the pressure lever system and located in the connecting area between the lifting hoop/pressure increasing lever/brake and locking lever.
[0032] [0032]FIG. 2 is a perspective plan view of an opened open-end rotor spinning device with an arrangement for absorbing internal forces and inserted into a comparable pressure lever system.
[0033] [0033]FIG. 3 is a perspective plan view of an arrangement as in FIG. 2 inserted into the pressure lever system of an expander roller, in particular the lifting hoop.
[0034] [0034]FIG. 4 is an exploded view of an arrangement in accordance with FIG. 3 in detail.
[0035] [0035]FIG. 5 is a perspective plan view of an alternative arrangement of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0036] An open-end spinning device 1 is shown schematically and in a lateral view in FIG. 1. In FIG. 1, the open-end spinning device 1 is shown in a state ready for operation, meaning that the rotor housing 2 , in which the spinning cup 32 of a spinning rotor 4 turns at a high number of revolutions, is closed by a cover element 11 .
[0037] In this embodiment, the rotor housing 2 is connected in a known manner by means of a pneumatic line 3 to a vacuum source (not shown). The vacuum is needed for spinning.
[0038] In a customary manner, the rotor shaft 5 of the spinning rotor 4 is seated in the wedge gaps of a support disk bearing 6 and is driven by a tangential belt 7 that extends over the length of the machine and in turn is acted upon by an expander roller 8 in the area of the rotor shaft 5 .
[0039] The spinning rotor 4 is further supported in the axial direction by an appropriate axial bearing 9 , such as a permanent magnet bearing.
[0040] In this embodiment, the rotor housing, as well as the bearing devices 6 and 9 are fixed in place on the spinning box housing 10 , which in turn is fastened on the base frame of the textile machine (not shown).
[0041] The rotor housing 2 , per se open toward the front, can be closed by means of a so-called conduit plate arranged in a pivotably seated cover element 11 .
[0042] The cover element 11 is connected with the spinning box housing 10 via a pivot shaft 12 . Furthermore, a sliver opening device is integrated into the cover element 11 . The sliver opening device in a known manner substantially comprises an opening roller rotating in an opening roller housing 13 , a sliver draw-in cylinder 16 , and an associated sliver compressor.
[0043] The opening roller is driven by a tangential belt 15 that rests against the drive wharve 18 of the opening roller, while the driving of the sliver draw-in cylinder 16 is performed via a driveshaft 20 extending over the length of the machine, or an appropriate worm/worm wheel arrangement 19 .
[0044] An expander roller 8 is assigned to each rotor shaft 5 that acts upon the tangential belt 7 in the immediate vicinity of the rotor shaft 5 .
[0045] As shown in the figures, the expander roller 8 is seated, freely rotatable, on a shaft 38 of an expander roller holder 39 , that can be pivoted around a shaft 40 extending parallel with the rotor shaft 5 . A spring element 41 , preferably a leaf spring, acts on the expander roller holder 39 , which presses the expander roller 8 against the tangential belt 7 .
[0046] Furthermore, a lifting hoop 22 of a pressure lever system 14 is connected to the expander roller holder 39 by means of a shaft 37 . The lifting hoop 22 has numerous embodiments. The lifting hoop 22 passes through an elongated hole recess 24 in a cross arm 25 of the spinning box housing 10 and is connected on its opposite side to a so-called pressure increasing lever 43 via a connecting means 27 .
[0047] In this embodiment, the connecting means 27 simultaneous acts together with a special guide and transfer element arranged on the brake and locking lever 23 . This guide and transfer element arranged at the end of the brake and locking lever 23 has different embodiments.
[0048] The guide and transfer element can either be embodied as an elongated hole guide 28 , as shown by way of example in FIGS. 1 and 2.
[0049] In accordance with FIG. 1A, the brake and locking lever 23 has on its end a fork guide element 30 , open at the bottom, as the guide and transfer element, in which the connecting means 27 , that connects the lifting hoop 22 with the pressure increasing lever 43 , is guided.
[0050] [0050]FIG. 1B shows a brake and locking lever 23 wherein the guide and transfer element is embodied as a strip-like extension. This strip 29 rests on the connecting means 27 from above.
[0051] Together with the guide and transfer element, the connecting means 27 constitutes an arrangement 21 on the brake and locking lever 23 , that prevents the transfer of forces from the lifting hoop 22 to the brake and locking lever 23 .
[0052] The arrangement 21 prevents forces from being transmitted via the lifting hoop 22 to the brake and locking lever 23 which could lead to the lifting of the brake and locking lever 23 , and therefore to a release of the arresting roller 45 of the cover element 11 .
[0053] In a customary manner, a rotor brake 46 is assigned to the rotor shaft 5 of the spinning rotor 4 , which is arranged underneath the tangential belt 7 . Preferably, the rotor brake 46 has two pivotably seated pincer arms 47 , 48 , which are pushed apart by means of a spreading spring.
[0054] In this embodiment, the pincer arms 47 , 48 each have a brake lining 51 , 52 on their end areas, or a sliding face on the opposite side.
[0055] In a known manner and therefore not represented in detail, a roller is seated in the area of the convergently arranged, sliding faces between the legs of a U-shaped brake beam 33 , and can be vertically displaced in relation to the sliding faces and in the process places the brake linings 51 , 52 of the rotor brake 46 against the rotor shaft 5 .
[0056] In a known manner, the rotor brake 46 and the expander roller 8 are connected with each other via a common activating mechanism in such a way that, when the spinning device is opened, i.e. in the course of the backward swing of the cover element 11 , the expander roller 8 is lifted off the tangential belt 7 against the force of the spring element 41 , and the brake linings 51 , 52 are simultaneously applied to the rotor shaft 5 .
[0057] As can be seen in FIGS. 1 to 3 , the brake and locking lever 23 has a locking recess 44 , in which an arresting roller 45 arranged on the cover element 11 is positively fixed in place when the cover element 11 is closed.
[0058] An advantageous embodiment of the present invention is represented in FIGS. 1 and 2 in a perspective plan view. Although different spinning devices are represented in the two drawing figures, these spinning devices do not differ in principle, so that components with the same reference numerals are identical in function.
[0059] The brake and locking lever 23 has a locking recess 44 , in which an arresting roller 45 arranged on the cover element 11 is positively fixed in place when the cover element 11 is closed.
[0060] The brake and locking lever 23 is pivotably seated on a shaft 35 and has on its end an elongated hole guide 28 , for example.
[0061] A connecting means 27 slides in the elongated hole guide 28 and connects the lifting hoop 22 with the pressure increasing lever 43 .
[0062] The elongated hole guide 28 of the brake and locking lever 23 constitutes a type of “idling arrangement” 21 . The elongated hole guide 28 is arranged and dimensioned in such a way that on the one hand, as indicated in FIG. 2, when the spinning device is opened, the expander roller 8 is dependably lifted off the tangential belt 7 by the lifting hoop 22 and the rotor brake 46 is actuated, but on the other hand no forces can be transmitted from the expander roller 8 to the brake and locking lever 23 .
[0063] It can be seen that the lifting hoop 22 is connected by means of a shaft 37 to the expander roller holder 39 which, in turn, is seated pivotably movable around a shaft 40 , and a shaft 38 supports the freely rotatably seated expander roller 8 .
[0064] The lifting hoop 22 further passes through an elongated hole recess 24 in a cross arm 25 of the spinning box frame 10 . In this embodiment, the elongated hole recess 24 is arranged and embodied in such a way that it constitutes a travel limiting means 17 , which prevents the expander roller 8 from being lifted over more than a maximum pivot angle α.
[0065] A detent element 26 can also be provided as the travel limiting means 17 . As can be seen in FIG. 5, this detent element 26 is seated on the shaft 37 of the lifting hoop 22 and slides with a guide pin 53 in the elongated hole recess 24 of the cross arm 25 .
[0066] A further embodiment of a device for preventing the transmission of internal forces to the brake and locking lever 23 is represented in FIG. 3. Here, a coupling arrangement 31 is present in place of the idling arrangement 21 . A coupling clip 49 has been inserted into a two-piece lifting hoop 22 , which non-positively connects the hoop elements 22 A and 22 B.
[0067] As can be seen in FIG. 4 in particular, the upper hoop element 22 A of the lifting hoop 22 , which is connected by means of the shaft 37 to the expander roller holder 39 , has two sliding faces, which extend divergingly upward. The sliding faces of the hoop element 22 A act together with two spring-elastic arresting tongues 50 at the coupling clip 49 of the coupling arrangement 31 .
[0068] The hoop elements 22 A and 22 B are connected by means of the coupling clip 49 which, for example, is made of plastic, in such a way, that at least shock-like introduced forces lead to a relative displacement of the hoop elements 22 A and 22 B, and therefore to a shortening of the lifting hoop 22 .
[0069] Forces, at least shock-like introduced forces, which have reached the lifting hoop 22 by way of the expander roller 8 , are absorbed by this shortening of the lifting hoop 22 , i.e. these forces are prevented from being transmitted to the brake and locking lever 23 .
[0070] A further advantageous embodiment of the device in accordance with the present invention is represented in FIG. 5. In this embodiment, an additional lever 34 is fixed on the brake and locking lever 23 , which has a locking recess 44 for the positive fixation of the arresting roller 45 arranged on the cover element 11 .
[0071] If during the course of a spinning process, a disruption of the spinning process, such as due to a yarn break occurs at one of the open-end spinning devices, an automatically operating piecing unit, a so-called piecing cart, is positioned at the respective spinning frame.
[0072] The piecing cart opens the spinning frame and cleans at least the spinning rotor.
[0073] The piecing cart lifts the brake and locking lever 23 by means of an appropriate (not shown) manipulator. In the course of this, the locking recess 44 of the brake and locking lever 23 is lifted off the arresting roller 45 of the cover element 11 , and the lifting hoop 22 of the pressure lever system 14 of the expander roller 8 is acted upon by the connecting means 27 in the sense of “lift off” expander roller 8 . In the course of lifting the brake and locking lever 23 , the brake beam 33 of the rotor brake 46 is simultaneously acted upon.
[0074] The rotor brake is actuated via the brake beam 33 , and the spinning rotor 4 is braked to a stop.
[0075] By means of a so-called opening arm arranged on the piecing cart, that engages the opening element 54 of the cover element 11 , the cover element 11 can be pivoted around the pivot shaft 12 , and the spinning device can be opened in this way.
[0076] Subsequent to the piecing process which is a known process and therefore not explained in greater detail, when the spinning frame is again to be accelerated up to the operational number of revolutions, the piecing cart acts on the pressure increasing lever 43 with an appropriate device.
[0077] A force is exerted on the pressure increasing lever 43 that is transmitted via the connecting means 27 to the lifting hoop 22 and lifts the latter. As can be seen in particular in FIG. 2, the lifting hoop 22 , which is connected via a shaft 37 to the expander roller holder 39 , in the process transmits a torque to the expander roller holder 39 , that is seated, pivotable around a shaft 40 , that leads to the expander roller 8 being pressed against the tangential belt 7 , and therefore to an increase of the friction between the tangential belt 7 and the rotor shaft 5 during the run-up of the spinning rotor 4 .
[0078] If a serious malfunction should occur during the spinning process, in particular an event which leads to the expander roller 8 being suddenly upwardly accelerated, the device 17 , 21 , 31 prevents the transmission of forces to the brake and locking lever 23 . With the device 17 , 21 , 31 of the present invention, it is assured that the cover element 11 of the spinning device 1 remains positively locked under all circumstances and cannot be opened by internal forces.
[0079] It will therefore be readily understood by those persons skilled in the art that the present invention is susceptible of broad utility and application. Many embodiments and adaptations of the present invention other than those herein described, as well as many variations, modifications and equivalent arrangements, will be apparent from or reasonably suggested by the present invention and the foregoing description thereof, without departing from the substance or scope of the present invention. Accordingly, while the present invention has been described herein in detail in relation to its preferred embodiment, it is to be understood that this disclosure is only illustrative and exemplary of the present invention and is made merely for purposes of providing a full and enabling disclosure of the invention. The foregoing disclosure is not intended or to be construed to limit the present invention or otherwise to exclude any such other embodiments, adaptations, variations, modifications and equivalent arrangements, the present invention being limited only by the claims appended hereto and the equivalents thereof. | A spinning device comprising a spinning box housing; a spinning rotor having a spinning cup on a rotor shaft; a cover element; a traveling belt acting tangentially on the rotor shaft; a rotor brake; a pivotable expander roller moveable within a maximum pivot angle via a pressure lever system connected to the brake gear of the rotor brake between an operative position when the spinning box is closed in an inoperative position wherein the expander roller is automatically lifted off the tangential belt and the rotor brake is applied to the rotor shaft when the spinning box is opened; a brake and locking lever having a locking recess in contact with an arresting roller arranged on the cover element; and an arrangement in the pressure lever system for absorbing shock-like forces acting on the expander roller and for preventing the forces from being transmitted to the brake and locking lever. | 3 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims the benefit of U.S. Provisional Application Ser. No. 60/706,625 filed Aug. 9, 2005, the entire contents of which are incorporated herein by reference.
BACKGROUND
[0002] Exemplary embodiments of the present invention provide a system and method for streamlining the flow of work and communications between personnel in a hospital radiology department. Additionally, exemplary embodiments of the present invention permanently memorialize communications and attempted communications between the various personnel involved in providing care for patients requiring the services of a radiology department, for example.
[0003] Conventionally, radiologists in a central “reading room” interpret exams received in a first-in first-served basis. For various reasons, the radiologists are often interrupted with requests for expedited examination of certain cases and/or requests for status on cases that are being examined or have yet to be examined. This drastically reduces the efficiency of the examination process and increases the stress level of the radiologists and all others involved in the process. Additionally, prior art systems often lack the capability to conveniently and permanently log communications both within the department and with outside personnel.
SUMMARY
[0004] The present application is designed to complement the application disclosed in. co-pending PCT application, Ser. No. PCT US06/10660, filed Mar. 23, 2006, the disclosure of which is incorporated herein by reference. The co-pending application describes an “Automated System and Method for Prioritization of Waiting Patients” also known as the Automated Radiology Triage System (“ARTS”) or “RadStream.” Exemplary embodiments of the present invention function as a part of the larger ARTS system and utilizes the output of the patient prioritization algorithm and process found in the co-pending application.
[0005] Exemplary embodiments of the present invention provide a computerized communications, logging, and workflow system that increases the efficiency of patient care in a hospital radiology department. The system includes a graphical user interface (“GUI”) that allows users to communicate within the radiology department, coordinate communications with personnel outside the department, and permanently record all communications, attempted communications, and reports. In conjunction with the ARTS patient prioritization system described in the copending application mentioned above, the exemplary embodiments of the present invention generate task lists for individuals involved in the process of obtaining, interpreting and reporting the results of radiological examinations. Additionally, exemplary embodiments of the present invention allow users to search the computerized records by various criteria to determine the real-time status of a case.
[0006] In a first aspect of the present invention, the system facilitates communications between personnel involved in providing radiology services to patients. The system provides a substantially automated mechanism for enabling electronic communications between personnel within the radiology department and utilizes a computerized process to coordinate communications with personnel outside the radiology department.
[0007] In a second aspect of the present invention, the system permanently memorializes/stores communications (i.e., keeps an electronic record of such communications that cannot be deleted, if at all, without specific access/deletion rights) and attempted communications. All memorialized electronic communications and reports are time stamped upon entry into the system. When a member of the radiology department staff utilizes the system to log a communication with outside personnel, that log entry is also time/date stamped. All communications data collected by the system is permanently stored and can be readily retrieved (by a user with proper access rights) using built in search functions.
[0008] It is a third aspect of the invention to generate computerized task lists for personnel involved in providing radiology services to patients. Through an interface with the Radiology Information System (“RIS”), ARTS obtains data pertaining to all outstanding ordered examinations as well as the associated patient data. ARTS prioritizes the patients using the algorithm described in the abovementioned co-pending application. The present invention displays the prioritized patient/exam list for each member of the radiology staff in the form of a worklist. The worklists are constantly updated as cases move through the process.
[0009] In a fourth aspect of the invention, the system allows users to determine the real-time status of an examination. Any user can search for a case by various criteria and determine its status. This function allows any user questioned by a patient or physician, for example, to ascertain and report the status of an examination without multiple phone calls and without speaking to the personnel performing each step of the process. Other aspects and advantages will be apparent from the following detailed description, the attached drawings and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 shows a diagram of the ARTS system networked to a number of user computers.
[0011] FIG. 2 shows a conceptual web site diagram for the ARTS system.
[0012] FIG. 3 shows an exemplary log-in page used to by a user to log into the ARTS system.
[0013] FIG. 4 shows an exemplary shot of a screen used by a technologist to view a worklist.
[0014] FIG. 5 shows another exemplary shot of a screen used by a technologist to view a worklist.
[0015] FIG. 6 shows an exemplary shot of a screen used by a technologist to input acuity data for a particular patient and particular exam.
[0016] FIG. 7 shows an exemplary MD contact information pop-up window that may be used to designate additional physicians to receive information regarding a particular patient, exam, report.
[0017] FIG. 8 shows an exemplary shot of a screen that may be used by an optional reading room assistant to assign particular exams to particular radiologist on duty.
[0018] FIG. 9 shows an exemplary shot of a screen used by radiologists to designate the location at which exams will be read and choose the types of exams that will be read.
[0019] FIGS. 10 a and 10 b show an exemplary shots of a screen used by radiologists to view the radiologist's worklist.
[0020] FIG. 11 shows an exemplary communication tool.
[0021] FIG. 12 shows an exemplary shot of a screen used by a physician priority link (“PPL”) operator to view the PPL operator's worklist.
[0022] FIG. 13 shows an exemplary case exam information popup used by a PPL operator to view exam information.
[0023] FIG. 14 shows an exemplary shot of a screen used by a PPL operator to convey exam information to a physician contact.
[0024] FIG. 15 shows an exemplary shot of a screen used by a PPL operator to view the PPL operator's worklist and cases on hold.
[0025] FIG. 16 shows an exemplary radiologist worklist screen with an exemplary window showing exams waiting to be conveyed to a physician contact.
[0026] FIG. 17 a shows an exemplary shot of a screen used to view conveyance records for a plurality of PPL operators.
[0027] FIG. 17 b shows an exemplary shot of a screen used to view conveyance records for a single PPL operator.
[0028] FIG. 18 shows an exemplary shot of a screen used to search exam records.
[0029] FIG. 19 shows an exemplary shot of a screen used to view the results of an exam records search based on date restrictions.
[0030] FIG. 20 shows an exemplary shot of a screen used to view the results of an exam records search based on Radiologist name and date restrictions.
[0031] FIG. 21 shows an exemplary shot of a screen used to view the record details for a particular exam.
[0032] FIG. 22 a shows an exemplary shot of a screen used to view patient information.
[0033] FIG. 22 b shows an exemplary shot of a screen used to view exam information.
[0034] FIG. 22 c shows an exemplary shot of a screen used to view acuity information.
[0035] FIG. 23 shows an exemplary shot of a screen used to view a contact log.
DETAILED DESCRIPTION
[0036] Exemplary embodiments described herein pertain to workflow and communications functions supplementing the existing ARTS system, which pertains to a computerized system and method for prioritizing radiology examinations. While the exemplary embodiments described herein pertain to workflow and communications in a radiology context, it will be apparent to those of ordinary skill in the art that the invention may be used in other areas of medicine; and may also be used in areas beyond the medical field.
[0037] The process in which a radiology examination is obtained, interpreted, reported, and conveyed requires several personnel, each potentially at a different physical location, to perform independent finctions in a certain order and in a timely manner. The process generally begins with a radiology technologist obtaining a study. The technologist may add comments to accompany the study. The study is passed to a reading room where a reading room assistant assigns incoming studies to radiologists. A radiologist interprets the study and records a report of the results of the examination. The radiologist either passes the report back to the reading room assistant, for reports to be conveyed to ordering physicians within the hospital, or passes it to the “Physician Priority Link” (“PPL”), a bank of telephone operators who convey reports to outside ordering physicians. The reading room assistant or PPL operator communicates the report to the ordering physician.
[0038] The present invention provides a computerized communications, logging, and workflow system that increases the efficiency of the process described above. Specifically, the present invention facilitates communications (both internal and external to the radiology department), permanently memorializes communications and reports, generates constantly updated worklists, and provides a search function. For the purposes of the present application, “permanently” memorializing or storing an electronic record involves keeping an electronic record that typically cannot be deleted, if at all, without specific access/deletion rights
[0039] As shown in FIG. 1 , ARTS exists as a software tool residing on a central server 20 , which may be accessed by one or more workstations operatively coupled to the central computer through a direct connection or a network connection (wired or wireless). For example, in the exemplary embodiment, the ARTS tool is a web-based application accessible by the plurality of workstations over the internet. In the exemplary embodiment, the plurality of workstations accessing the ARTS tool includes “Technologist A” 22 at an outpatient center A, “Technologist B” 24 at another remote outpatient center B, and “Technologist C” 26 at a hospital emergency room. Each of these remote outpatient centers and/or hospital emergency rooms may also include a front desk clerk/receptionist workstation 28 . A PPL operator 30 has access to the ARTS system as well as a reading room assistant 32 . Finally, a number of radiologists 34 , 36 have access to the ARTS system as will be described in further detail below. It is within the scope of the invention that various sub-roles are also available, such as radiology staff, resident, and fellow.
[0040] As shown in FIG. 2 , operation of the ARTS tool on the server 20 initially provides to anyone accessing its home page 38 , a login page 40 which is shown in detail in FIG. 3 . Once logged in, a roll selection object 42 will be implemented which will either automatically determine the roll of the individual logging in or allow the individual to select a roll from a list of rolls. Users selecting technologist or radiologist roles are directed to a work location and service selection object 43 . The user will then be provided with a home page 44 which is personalized for the individual user and the user's roll. In the exemplary embodiment, the available roles include a technologist, a reading room assistant, a radiologist, a PPL operator, a front desk clerk/receptionist, and system administrator.
[0041] Generally, the process overview includes a technologist (in an outpatient center, for example) accessing a technologist's object 46 on the ARTS system. The technologist views the technologist worklist, shown in detail in FIGS. 4 and 5 , to determine the order in which patients should be seen. As disclosed in the abovementioned co-pending application, the worklist displays the patients in priority order. In the exemplary embodiment, the technologist is able to filter the list of patients and exams to show only his or her patients who are to be examined on a certain piece of equipment, thus reducing the amount of irrelevant information displayed. In a further embodiment of the invention, the worklists are automatically generated based on an individual's qualifications and assignments.
[0042] The technologist completes an initial exam of the patient and enters the information using an enter exams object 47 . The enter exams object 47 includes inputting certain acuity level factors and optional comments as shown in detail in FIG. 6 . The technologist may optionally utilize an additional MD contact info popup 68 , shown in detail in FIG. 7 , to have the report of the examination sent to another physician. This is useful when the data obtained RIS indicates that only one physician should receive the report of the examination but the patient or the referring physician informs the technologist that the exam report should also be sent to one or more other physicians.
[0043] In one exemplary embodiment, a reading room assistant at optional workstation 32 accessing an optional reading room assistant object 48 would monitor the prioritized list of patients, shown in detail in FIG. 8 , and assign cases in the prioritized list to available radiologists based upon the priority of the case and the availability of the particular radiologist. Similar to the technologist's worklist, the display can be adjusted to show only the pending examinations of certain types. The reading room assistant utilizes an assign exams object 100 to assign exams and an unassign exams object 102 to unassign exams when necessary. For radiology departments that do not use reading room assistants, the reading room assistant role can be combined with the technologist role. The ARTS system also allows the radiologists at workstations 34 and 36 through the “Radiologist” object 50 to view the prioritized list of patients and to assign cases in the prioritized list to themselves. It is also within the scope of the invention that a radiologist may be assigned to a particular case at any point in the process by any authorized user, including by the technologist or the radiologist himself. This increases overall efficiency because it allows examinations to be directed to a radiologist who is already familiar with a particular patient.
[0044] If a reading room assistant is used, he or she may also have available a convey reported exams object 104 . The reading room assistant uses this function when he or she speaks with an ordering physician and conveys an examination report. The reading room assistant performs this function for in-house referring physicians.
[0045] Each radiologist, at workstations 34 and 36 , will then access the ARTS system through a radiologist object 50 by selecting his or her physical working location from drop-down box 374 and the types of services he or she will be reading from a list of services 373 , both of which are shown in FIG. 9 . From here, the radiologist is able to access the assigned list of cases he or she is to examine, shown in FIG. 10 a , access all the records and files necessary to perform the particular examination, including any comments from the technologist, and then record his or her report of the examination into the ARTS system, subsequent to which the patient will be removed from the prioritization list and, as appropriate, added to the PPL worklist. As mentioned above, the radiologist can self-assign cases using an assign exams object 100 . This capability allows a radiologist to utilize a slow period in his or her workflow to assist a colleague who is receiving a surge of cases, thereby increasing the efficiency of the radiology department as a whole. The radiologist can also unassign an examination by using an unassign exams object 102 . A convey reported exams object 104 is available to the radiologist so that he or she can log that the report of an examination has been conveyed to an ordering physician. This function is useful in cases where the radiologist and the ordering physician have a conversation and it is unnecessary for either the reading room assistant or PPL operator to contact the ordering physician to convey the examination report. An add MD contact record 70 may be available for both a reading room assistant and/or a radiologist.
[0046] For cases in which more than one practitioner reviews a single exam, such as a supervising radiologist reviewing the report of a trainee or a case in which consultation among two or more radiologists is sought, the present invention provides a communication tool shown in FIG. 11 . This tool permits the consulting or reviewing radiologist to send another practitioner a message comparing a preliminary report 379 e to a more recent report 379 d , along with one or more comments 379 c.
[0047] After the radiologist interprets the study and enters the report, either by manually typing it or by using the optional voice recognition capability (or entering it through any other electronic media), the case is transferred off of the radiologist worklist as shown in FIG. 10 b to the PPL worklist shown in detail in FIG. 12 . The PPL operator views the case information using an exam info popup object 98 , shown in detail in FIG. 13 , within the “PPL Operator” object 52 on the “PPL Operator” workstation 30 . The PPL operator logs any communication or attempted communication with the referring physician using the screen shown in FIG. 14 . The PPL operator attempts to contact the ordering physician and convey the results of the examination. If the physician is not available, the PPL operator uses the system to log the attempted communication and the case is transferred to “hold” status, which is effectively another worklist listing cases for which contact has been attempted but the report has not been conveyed to the ordering physician. The PPL operators use the hold worklist to access patient/exam reports when the ordering physician calls back or to reattempt to contact the ordering physician at a later time. A PPL worklist with a case on hold is shown in FIG. 15 . The reading room assistants may perform a similar function for in-house referring physicians, or the radiologist may do this himself or herself.
[0048] This workflow process allows a decentralized call center to handle asynchronus communications about multiple cases smoothly (that is, any operator “A” may initiate and log a communication attempt; when a response call comes in, any operator “B” can pick up the communication thread for that case, complete it, and log the conveyance). With ARTS, all PPL communication, including routing the case to the PPL operator, occurs in the background, with no effort required by the radiologist. That is, ARTS automatically collects the report from RIS as soon as it's available, routes it to the PPL opertor with all other required information, the PPL operator contacts the referring physician, conveys the report findings, and logs that communication, without involving the radiologist at any point. This is true for both positive and negative STAT cases. It is estimated the radiologist saves approximately 5 minutes per positive STAT case and 135 seconds per negative STAT case by using ARTS instead of the conventional paper-based system. The PPL operators and reading room assistants (who perform the same function as the calling service, contacting in-house referring MDs with reports, brokered by ARTS) save the radiologist an estimated 3-5 minutes for each positive STAT case by being empowered to communicate report results directly to referring MDs, rather than having to connect referring MDs with the radiologist (i.e. paging and waiting for both the referring MD and radiologist to become available simultaneously).
[0049] Such conveyance of reports by the PPL operators may be monitored through use of the functions shown in detail in FIGS. 16 ., 17 a and 17 b . The radiologists themselves can monitor the status of reported case by opening window 520 shown in detail in FIG. 16 . Window 520 provides a status chart 522 that identifies the exams that have been reported, but have not yet been conveyed to the ordering or referring physician. If any one reported exam is not conveyed within 30 minutes of its report, animation 524 spins to alert the radiologist of the delay. Additionally, the conveyance of cases may be monitored according to PPL operator, as shown in detail in FIGS. 17 a - 17 b . By identifying the name of an individual PPL operator 526 and range of dates 527 from the screen shown in FIG. 17 a , a user can view the entire list of reports 529 that were conveyed by the PPL operator 526 within the range of dates 527 , as shown in FIG. 17 b . A detail of each report can be obtained by clicking record “Detail” button 530 .
[0050] The search all exams object 66 shown under the “Technologist” object in FIG. 2 may be made available to all users. Details of the available search criteria are shown in FIG. 18 . Historical records can be searched by clicking on “History” button 357 , which take the user to history search screen shown in detail in FIG. 19 . A user can easily choose to search only the cases reviewed by a particular radiologist by clicking on the “My Cases” icon 353 , which will take the user to the “My Cases” report page shown in FIG. 20 . Here, the user can choose the reviewing radiologist name 536 and a range of dates 538 .
[0051] Once a particular examination has been located, the detailed exam information may be viewed by clicking the “Details” button 535 to view all available data about the examination. This takes a user to a screen displaying detailed information relating to an exam at each stage of the process (including “Exam Status” information 540 , “Process By” information 542 , “Status Date Time” information 544 , and “Note” information 546 ), the “Report Text” 539 , and the “Contact Record History” 548 . An example of such detail is shown in FIG. 21 .
[0052] Another way to access information pertaining to a particular exam is to access the “View Exam Detail Info” object 64 , which provides patient information 88 (name, date of birth, location, home), examination information 90 (exam, physicians, radiologist, technologist), examination report 92 (patient, physicians, radiologist, exam impression, exam result), exam acuity scores 94 (technologist comment, acuity score, technologist name, service type), additional MD contact information 68 , and the exam contact record 96 (message, name and position of person contacted, date, time). Examples of such details are shown in FIGS. 22 a - c.
[0053] The patient info 88 available for each examination is shown in FIG. 22 a . The “Exam Info” 90 available for each exam is shown in FIG. 22 b . The “Exam Report” 92 may include all preliminary and final radiologists'reports. FIG. 22 c shows the “Acuity” data 94 available for each examination. FIG. 23 shows the “Exam Contact Record” 96 available for each examination.
[0054] All users have the ability to change the patient's waiting status using the “Change Patient Waiting Status” object 72 . This object provides input into the prioritization algorithm of the abovementioned copending application as well as changing the patient waiting status indication available in the patient's “Exam Acuity Scores” object 94 .
[0055] The “Add MD Contact Record” 70 may be available in the objects for the “Reading Room Assistant” 48 and “Radiologist” 50 . The ARTS system provides the capability for each individual working with the system to provide contact reports such as physician contact records to memorialize all communications between the various individuals for recordkeeping purposes. For example, if a radiologist telephones an ordering physician to discuss a case, the system can be used to record notes of the conversation. This provides a permanent record of the contact that is easily accessible along with other patient records via ARTS.
[0056] A similar function is available to other users of the system. For example, if an ordering physician calls to obtain the status of an exam, the system can be used to note the conversation by whichever user speaks to the physician on the telephone. Finally, the Physician Priority Link (“PPL”) operators log each communication and each attempted communication with physicians. All records of communications are automatically time-stamped when they are submitted. The system permanently memorializes both preliminary and final reports examination reports in addition to the communications logs.
[0057] The “System Administration Pages” object 56 includes finctions such as “User Management” 74 , “Service Management” 76 , “Facility Management” 78 , contact info management 80 , “PPL Report” object 82 , “Radiologist Report” object 84 , and “Service Report” object 86 .
[0058] Because all events are logged with the date/time-stamp and user, the system can be used to identify and locate any individual involved in any step of the process. For example a technologist who did not properly complete a study can easily be identified and his or her contact information is available directly from the system. This capability can save a significant amount of time for radiologists and reading room assistants. The date/time-stamping feature also permits operational analysis of the flow of work through the radiology department as well as real-time monitoring of workflow.
[0059] FIG. 3 shows an exemplary login screen on which the user is required to input both a user name 300 and a password 302 and then select “Login to ARTS” 310 . Additionally, the login screen provides access to functions such as “Change Password” 304 , forgotten password retrieval 306 , providing feedback to the system administrator 308 , and news and updates 311 regarding the invention.
[0060] FIG. 4 is an exemplary embodiment of the radiology technologist worklist on a technologist workstation. The patients to be seen by the technologist are listed in priority order as determined by the ARTS prioritization system. For each patient, the worklist displays the patient's name 330 , medical record number 332 , date of birth 334 , and secondary service 336 . For each exam, the worklist displays the RadStream “Status” 312 , “Procedure” 314 , modality 316 , “Accession” number 318 , “Service” 320 , “RIS Status” 322 , “Radiologist” 324 , “Ordering MD” 326 , and “Type” 328 . Some fields are blank because the applicable data is obtained at a later step in the process (e.g., the radiologist field 324 is filled when a radiologist is assigned to interpret the exam). Additionally, the technologist can search all exams. Fields of search include “Patient Name” 338 , medical record number 340 , “Accession” number 342 , “Service” 344 , “Modality” 346 , “Location” 348 , “Priority” 350 , “Patient Type” 352 , “Status” 354 , and “View” 356 . It is within the scope of the invention that the search fields may include drop-down menus listing available subheadings, as shown in FIG. 18 .
[0061] FIG. 5 shows an exemplary screen shot of the technologist workstation. The status column 359 indicates “Reported” for a previously dictated examination and “Pending” for the examinations that are ready for the technologist to enter in ARTS. The “RIS Status” column 361 indicates “Approved” for the previously dictated and signed examination and “Completed” for the exam just completed in RIS by the technologist. The technologist selects “Enter” 358 to populate the acuity score screen.
[0062] FIG. 6 shows an exemplary screen shot of the acuity data viewed on a technologist workstation. The technologist can view or update the answers to questions 360 which will be used by ARTS to determine the patient's position in the priority list. The technologist also specifies whether the examination report is to be conveyed to the ordering physician via the PPL. Additionally, the technologist may optionally review or enter comments in field 362 . For example, a technologist may add a comment stating that a patient was not able to be properly positioned during an examination due to pain. In the past, this would be communicated to the radiologist via a written note or a telephone call. The present invention allows the technologist to type the comment directly into the computer system. The radiologist views the technologist's comments when he or she selects the case for interpretation. The present invention increases efficiency because the comment accompanies all of the other patient information and examination data sent to the radiologist. The radiologist is not disturbed by a phone call and the note cannot be misplaced. All comments are automatically time-stamped when they are submitted. It is within the scope of the invention that comments and other information may be input directly into the system using voice recognition software (or other form of electronic media), reducing the time that personnel spend on administrative tasks.
[0063] The technologist may also select “Additional Contact Info” 364 to have the report of the exam sent to an additional physician (see FIG. 7 ). When all of the data entry and review is complete, the technologist selects “Submit Selected Exams” 365 to send the completed examinations to the radiologist's worklist.
[0064] FIG. 7 shows an exemplary screen shot of the “Additional Contact Info” function 366 . The technologist enters information in fields 370 for the physician who should receive the report and selects “Submit” 368 .
[0065] FIG. 8 shows an exemplary screen shot of the radiologist reading room worklist. This list of unassigned cases for examination by a radiologist may be accessible by both the reading room assistant and the radiologists. The exams are listed in order of acuity as determined by ARTS. The “Status” column 359 indicates “Entered,” meaning that the examinations are ready for interpretation by a radiologist. The “Assign” buttons 372 allow the reading room assistant, technologist, or radiologists to assign cases to specific radiologists for interpretation and dictation. In addition to viewing the list of cases ready for interpretation, the reading room assistant can monitor for examinations that have been entered into ARTS but have not been completed in RIS. This capability prevents an examination from being inadvertently overlooked for a long period of time due to a minor error when the examination is obtained. When the reading room assistant is alerted to a case in this status, he or she contacts the technologist who corrects the problem, and the case is removed from the alert list.
[0066] FIG. 9 shows an exemplary screen shot of the screen that may be used by individual radiologists to identify the physical location at which he or she will review exams, and choose the type of exams he or she will review from a list of exams 373 . It is within the scope of the invention for physical location to be identified from a drop-down box 374 containing a list of locations for a particular health system or network of health systems.
[0067] FIGS. 10 a shows other exemplary screen shots of the reading room worklist. Under the heading “Current Radiologist: Cases Assigned for Dictation” 374 are listed the cases assigned to the radiologist who is logged in to the system. The radiologist can remove a case from his or her worklist by selecting the “UnAssign ” button 376 , which will move the case back to the list of examinations awaiting assignment to a radiologist and change its status to “Entered.” The “Status” column 359 under the “Cases Assigned for Dictation” 374 indicates “Assigned,” meaning that the case has been assigned to a radiologist for interpretation. All ARTS screens then indicate that the assigned radiologist is actively interpreting the study. This function prevents wasted time due to more than one radiologist commencing an interpretation of a case and later discovering that his or her colleague has also begun an interpretation of the same case. Once the interpretation is complete, the radiologist either manually types the report into the system or dictates it using optional voice recognition software.
[0068] FIG. 10 b shows an exemplary screen shot of the reading room worklist after the case assigned to the radiologist was interpreted and dictated. The case was removed from the “Current Radiologist: Cases Assigned for Dictation” 374 list and was transferred to the PPL worklist shown on FIG. 12 .
[0069] FIG. 11 shows an exemplary screen shot of a communication tool feature that may be used when more than one radiologist reviews a single exam. Using this tool, a consulting or supervising radiologist may search for particular exam for consult or education by using search box 377 a . When the target exam is found and reviewed by the consulting or supervising radiologist, he or she can send a comparison of a “Preliminary Report” 379 e and a more recent report 376 d to a second radiologist. It is within the scope of the invention that the second radiologist may be identified from a drop-down box 379 a listing radiologists of a particular health system or network of health systems. The radiologist sending the comparison may also choose a reason for the comparison 379 b and/or enter comments regarding the comparison in comment field 379 c . It is also within the scope of the invention that the consulting or supervising radiologist can enter any type of comment in the commend field 379 c based merely upon an evaluation of the target exam (with or without a comparison to another exam), or based upon other considerations.
[0070] FIG. 12 shows an exemplary embodiment of the PPL operator worklist on the PPL operator workstation. An examination report that is to be conveyed to the ordering physician via the PPL (as specified by the technologist on the screen shown in FIG. 6 ) automatically appears on the PPL worklist when it is ready to be conveyed. ARTS automatically obtains the examination report from RIS and makes it available to the PPL operator. The PPL operator views the details of a case by selecting from a list of patients'names 378 . It is within the scope of the invention that the PPL operators are signaled that a new case has appeared on their worklist by an audible alert.
[0071] FIG. 13 shows an exemplary screen shot of the “PPL worklist detail” 380 of the case selected by the PPL operator. The PPL operator has access to contact information for the ordering and referring physicians 382 and the radiologist 384 who interpreted the exam, as well as patient information 385 . The PPL operator will attempt to contact the ordering physician. If the physician is available and the report 387 is conveyed, the PPL operator selects “Convey all” 386 , causing the case to be removed from the worklist and populating the contact log. If the physician is not available to receive the report, the PPL operator selects “Hold all” 388 . If there is a previous contact record it appears on the contact history 389 portion of the screen. The system also allows the PPL operator to fax or print the report by selecting the appropriate button, 381 or 383 .
[0072] FIG. 14 shows an exemplary screen shot of the PPL operator worklist detail screen which is accessed when the PPL operator selects “Hold all” 388 . The PPL operator selects one of four options 391 , types a brief note about the attempted contact 390 , and then selects “Submit” 392 . The case is moved to the “PPL Operator Cases on Hold: Contact Attempted” list 394 as shown in FIG. 15 . If the physician calls the PPL facility to obtain the examination report, any PPL operator can access the case detail screen by selecting the case 396 from the list, and see all prior contact attempt information as well as all exam information. That PPL operator then “conveys” the examination which then disappears from the active PPL worklist screen. The reading room assistant performs similar functions for in-house referring physicians.
[0073] FIG. 16 shows an exemplary screen shot of panel 520 hat may be used by a radiologist to monitor the status of exams that have been reported by the radiologist, but have yet to be conveyed by the PP 1 operator. Panel 520 provides a chart 522 identifying the exams yet to be conveyed and the wait time for each. FIG. 16 also shows animation 524 which, according to an exemplary embodiment, “spins” to alert the radiologist if any one reported exam has not been conveyed within a specified length of time.
[0074] FIGS. 17 a - 17 b show yet another exemplary screen for monitoring the conveyance of reported exams. The exemplary screen shown in FIG. 17 a permits a user to search conveyance records by PPL operator 526 , within a specified range of dates 527 . To choose the records for a specific PPL operator, the user may click “Detail” button 528 , which would take the user to a screen such as that shown in FIG. 17 b . From here, the user may choose from a list of exams 529 conveyed by the chosen PPL operator by clicking on “Record Detail” button 530 .
[0075] FIG. 18 shows an exemplary screen shot of the search functions available to any user. Searches can be performed by “Patient Name” 338 , medical record number 340 , “Accession” number 342 , “Service” 344 , “Modality” 346 , “Location” 348 , “Priority” 350 , “Patient Type” 352 , “Status” 354 , and “View” 356 . The search function allows users to search and review entered, pending, reported, completed, and conveyed exams. Drop down menus may provide available subheadings. Alternatively, a user may search historical exam records by clicking “History” button 357 , which would take the user to a screen such as that shown in FIG. 19 . From here, the user may access a list of exams 351 pertaining to a specified range of dates 532 . To view the detail information for any of the exams, the user may click the “Details” button 535 corresponding to the chosen exam. Yet another way in a user may search the exams records is by activating the “My Cases” icon 353 (see FIG. 18 ). This would take the user to a screen such as that shown in FIG. 20 , from which the user may choose from a list of reviewing radiologists 536 and specify a range of dates 538 . Again, to view the details from any of the resulting list of exam records, the user need only click on the corresponding “Details” button 535 . An example of such detail is shown in FIG. 21 , and provides, in addition to the text of the exam report 539 , the status history 540 of the exam as it was processed, the person 542 who performed each step in the processing of the exam, the date and time 544 of each stage in the process, and any notes 546 corresponding to each stage in the processing. Any messages that were sent through the system regarding the exam are also noted under the “Contact Record History” heading 548 .
[0076] Because the search function is available to any user, any user can respond to a request for the status of an examination. This increases efficiency of the department as a whole because the radiologists are not disturbed by calls requesting status. Customers are more satisfied because they can learn the status of their exams quickly without having their phone calls transferred numerous times.
[0077] In another example of the application of this capability, the front desk clerk/receptionist can search for the real-time status of any examination at the request of a patient. The front desk clerk/receptionist can use the data retrieved to inform the patient of the current status of his or her radiology report(s), help the patient decide whether to wait, and inform him or her when to expect a call from his or her physician, whether radiology has begun to try to communicate the examination results to his or her physician, and whether the physician was successfully contacted.
[0078] FIG. 22 a shows an exemplary screen shot of the RIS “Patient Info” 398 accessible through ARTS. All RIS patient data is available for viewing using ARTS. The data includes the patient's name 400 , date of birth 402 , age 404 , medical record number 406 , waiting status 408 , primary physician 410 , home phone number 412 , home address 414 , and current location 416 .
[0079] FIG. 22 b shows an exemplary screen shot of “Exam Info” 418 accessible through ARTS. All examination data available from RIS can be viewed using ARTS. The data includes specific information about each exam 420 , as well as physician information 422 and radiologist information 424 . It is also within the scope of the invention that contact information is available in the system for various personnel involved in the gathering, interpretation, and reporting of radiology examinations, such as technologists, radiologists, and referring physicians.
[0080] FIG. 22 c shows an exemplary screen shot of a patient's “Acuity” data page 425 . The “Patient Waiting” status 426 can be updated at any time by any user, including the front desk clerk. It is within the scope of the invention that the estimated time to radiology report availability as calculated by the system disclosed in the abovementioned copending application is available to all users.
[0081] An exemplary contact log is shown in FIG. 23 including the date/time stamp 500 , user 502 , and message 504 relating to each contact made regarding a particular exam. The screen allows another contact record to be entered using the comment block 506 , radiology contact 508 , and contact time 510 .
[0082] Summary of advantages of ARTS communications and workflow functions:
Function Feature Note Potential Impact Paperless workflow Eliminates paper Smooth Workflow requisitions No lost requisitions Legible technologist notes Decreased confusion Decentralized study acquisition Decentralized study interpretation Real-time workload balancing Transparent workflow Workflow surges addressed If one area is swamped, less busy early radiologists can step in Proactive elimination of bottlenecks Improved patient care Automated triage Ensures appropriate and Patients treated first: timely delivery of care sickest needing subsequent tests needing further treatment waiting for discharge Improved patient care Improved hospital workflow Improved patient satisfaction Increased efficiency of care Increased referrals Increased revenue Effective electronic Supplies pager number, Reduced radiologist and referring tools to contact phone numbers, and brokers physician frustration referring physicians contact between radiologists and referring physicians To communicate important Improved communication findings or questions Reduced workflow interruptions Increased efficiency Improved patient care, satisfaction Communication tools Covers important Improved clarity as to which information in addition to caregivers have been notified of RIS status and radiology critical findings reports Facilitated communication Simplified process for communicating results - reduced medical errors Permanent communication Permanent log of what was said to log whom, and when Also logs unanswered Improved medicolegal pages, and calls never documentation in the event of returned to radiology communication failures: by documenting failed and repeated attempts by radiology to reach responsible caregivers, system offers increased medicolegal protection to radiology Reduced duplication of efforts by staff to communicate important findings Location and status of Useful to caregivers both Enhanced tracking of patients patients throughout within and outside the throughout radiology workflow department radiology department Allows any radiology staff member to answer calls from referring physicians regarding patient location and study status - eliminates multiple call transfers, eliminates time wasted locating patients Enhanced radiology department image as providing coordinated, organized, informed care Increased referrals Waiting status of Does patient need final Improved communication between patient radiology report or to speak patients and their physicians to their physician before leaving department? No “orphaned” patients in the waiting room Shorter wait times Improved patient and referring physician satisfaction Increased referrals Electronic capture of Examples: “Patient was Improved communication between technologist comments difficult to position”, technologists and radiologists and notes “Please send copy of report to Dr. Smith”, “Pain located at base of thumb” Eliminates loss of handwritten notes Guarantees that appropriate information is available to the radiologist at time of interpretation Improved patient care Contact Information Who is included: Time Saver Radiologist Technologist Referring physician Patient What is included: Decreased frustration Pager Numbers Phone Numbers Locations Users can locate staff quickly Users can contact staff quickly Clarifies which staff is involved in each case Improved communication Improved patient care Permanent capture of Useful both to private Increased clarity regarding changes all preliminary reports, practices and academic to radiology reports subsequent versions, centers and addenda Documents who said what, when, and to whom Eliminates ambiguity about radiology resident preliminary interpretations Clarifies timing of different report versions Decreases medicolegal exposure
[0083] Following from the above description and invention summaries, it should be apparent to those of ordinary skill in the art that, while the systems and processes herein described constitute exemplary embodiments of the present invention, it is to be understood that the invention is not limited to these precise systems and processes and that changes may be made therein without departing from the scope of the invention as defined by the claims. For example, while the exemplary embodiments are described with reference to a radiology case management system, it will be apparent to those of ordinary skill in the art that other medical (or even non-medical) case management systems (such as, for example and without limitation, emergency room case management systems, pharmacy case management systems, medical testing case management systems, and the like) will also fall within the scope of certain aspects of the present invention as claimed.
[0084] Additionally, it is to be understood that the invention is defined by the claims and it is not intended that any limitations or elements describing the exemplary embodiments set forth herein are to be incorporated into the meaning of the claims unless such limitations or elements are explicitly listed in the claims. Likewise, it is to be understood that it is not necessary to meet any or all of the identified advantages or objects of the invention disclosed herein in order to fall within the scope of any claims, since the invention is defined by the claims and since inherent and/or unforeseen advantages of the present invention may exist even though they may not have been explicitly discussed herein. | Exemplary embodiments of the present invention perform workflow and communications logging functions in a hospital radiology department, free-standing imaging center, or other institution providing imaging services. The exemplary embodiments allow logging of communications and attempted communications both within the department and with personnel outside the department. The logs permanently memorialize the communications and can be viewed with the patient's other computerized records. The exemplary embodiments also assign and tracks the status of work as it progresses through a multi-step process. The exemplary embodiments generate and update lists of assigned tasks for the various individuals involved in providing radiology services to patients. For radiologists, the task lists are created by filtering the lists of cases available for interpretation. The lists are updated to reflect the current pending cases in real time. Users can query the system to determine the exact status of any case. Additionally, the system permits computer-based communications to accompany radiological studies throughout the process. | 6 |
BACKGROUND OF THE INVENTION
(1) Field of the Invention
The present invention relates to a square-meshed net used for fishing, agriculture, sports, and the like and a method and machine for knotting the same.
(2) Description of the Prior Art
In what is called an English knotted net, the warp and weft run in zigzag fashion when the net is in an unfolded condition. The warp and weft in their connection at the knot are adapted to turn. The mesh so knotted is formed in a rhombic shape. However, for fishing, agriculture, and sports, the direction of the warp and weft forming the rectangular net is often required to be parallel to each side of the rectangle. In other words, the form of the mesh should be square with the overall shape of the net.
For this purpose, the English knotted net has been used so far only by being cut diagonally to prepare a square-meshed net. However, this requires a great deal of labor and material. Moreover, even with a thus manufactured square-meshed net, warp and weft run in zigzag, so that if the net is unfolded and loaded with increasing tension to warp and weft, knots connected to warp and weft are liable to lose balance and to be lacking in strength as a net. Such a net would have little or no utility.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a square-meshed net, in which the group of warp runs straight on and the group of weft runs slantingly to cross each other, and the weft knotted with the wrap travels in a certain horizontal direction to be knotted with next warp at every knotting and knotted to flat board which warp and weft cross each other at a right angle when the net is unfolded.
Another object of the present invention is to provide a square-meshed net, in which at a knotting stage, the group of weft (the group of warp) is arranged along the generating line of a cylinder and the group of warp (the group of weft) is arranged spirally along the cylinder, and warp and weft cross each other and warp (weft) crossed with weft (warp) is cylindrically knotted at every knotting so as to be knotted with next weft (warp), thus providing a square-meshed net which warp and weft meet at a right angle with the net unfolded in flat, by either cutting the group of weft along a line of warp or cutting the group of warp along a line of weft.
Further object of the present invention is to provide a square-meshed net, in which weft is turned twice and formed to be S-shaped loop and knotted with warp.
Still further object of the present invention is to provide method and a machine knotting a square-meshed net which warp and weft meet at a right angle under the unfolded condition.
These and further objects and advantages of the present invention will become more apparent upon reference to the following specification and drawings. It should be understood that these drawings are solely descriptive and not limiting the scope of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1 to 7 relate to the first embodiment of a flat type net knotting machine:
FIG. 1 is a partial section of an elevational view; FIG. 2 is a partial section of a side view; FIGS. 3A to 3I are schematic illustrations showing the sequential steps of net knotting process; FIG. 4 is a frontview showing knots before fastening; FIG. 5A is a front view showing knots after fastening; FIG. 5B is a back view of the former; FIG. 6 is a front view showing the net knotted as it is; FIG. 7 is a front view showing the net which is unfolded to be a square-meshed condition.
FIGS. 8 to 17 relate to the second embodiment of a circular type net knotting machine:
FIG. 8 is a perspective view showing the framework of the net knotting machine; FIGS. 9 to 11 are perspective views showing the details of respective parts; FIGS. 12A and B are perspective views showing the main portions of the upper hook; FIG. 13 is a partial section of a front view showing the vicinity of the upper portion of the net knotting machine, FIG. 14 is a brief partial section of a front view showing the vicinity of the lower portion of the machine; FIG. 15 is a partial section of a front view showing the outer circumference of the lower portion of the machine; FIGS. 16 and 17 are perspective views showing the net as it is knotted to cylindrical condition.
DESCRIPTION OF THE PREFERRED EMBODIMENT
First Embodiment (Refer to FIGS. 1 to 7)
In FIG. 1, warp 1 is pulled out from a warp package (not shown) and led forward to a warp guide member 103 and weft 2 is wound around a bobbin housed in a bobbin case 108 and led backward to a guide hole of the bobbin case. Numeral 104 is an upper hook and numeral 109 is a lower hook. Each of the above-mentioned members is constituted as similar to the conventional english knotted net manufacturing machine. These members are arranged in a right angle direction (right and left direction) to the surface of paper in plural sets. Each bobbin case 108 is loaded on a concave stopper 105a of a pair of a case receiver 105 in front and rear fixed in a case 106 similarly to the conventional net knotting machine and arranged in the middle of a pair of the case receiver 105 in front and rear and corresponds to a concave stopper 107a arranged in front and rear lines of a travelling case receiver 107. And, a logarithum of the concave stopper 107a is equal to the number of the bobbin case 108 and a logarithum of the concave stopper 105a is formed to be superior by one pair to the number of bobbin case 108.
At the middle lower part of the travelling case receiver 107, a couple of a supporting legs 111 are hanged on right and left downwards and are engaged with a long guide hole which passed through right and left directions in the case 106. The lower end of the leg is engaged with a cam slot 113 cut in on an eccentric cam 112 which is adapted to make one turning during one cycle of net knotting movement. And, the travelling case 107 makes reciprocating movement in the right and left directions by one pitch of the concave stopper 107a while the case makes up and down movement. Thus, a flat type net knotting machine provided with those above mentioned member is formed.
Then, the net knotting steps by means of this net knotting machine will be described, referring to FIGS. 3A to 3I. In these drawings, a circle or circular arc illustrated on the upper part of the drawings shows the overhead view of the direction of the upper hook 104 and the turning direction, where the warp 1, weft 2, warp guide member 103, upper hook 104 and lower hook 109 are viewed from the left side, while the case receiver 105, case 106, travelling case receiver 107 and bobbin case 108 are viewed from the front.
A Starting Position (FIG. 3A)
The upper hook 104 looks toward the warp guide member 103; the bobbin case 108 is loaded on the concave stopper 105a of the case receiver 105, and the concave stopper 107a of the travelling case receiver is located on a level lower than the bobbin case 108 and a little to the right of the bobbin case 108.
Step B (FIG. 3B)
The upper hook 104 turns three quarter to the counterclockwise direction and waits for a rise of the bobbin case 108. The travelling case receiver 107 begins travelling leftward during a rise movement.
Step C (FIG. 3C)
The travelling case receiver 107 rises, onto which the bobbin case 108 loaded on the case receiver 105 is transferred, and travels leftward continuously. The upper hook 104 makes a half turn to the clockwise direction and hooks the weft 2 which is risen by the rise of the bobbin case 108.
Step D (FIG. 3D)
The upper hook makes more a quarter turn to the clockwise direction, looks toward the warp guide member 103 and hooks down the warp 1 in the reverse direction of the weft 2, interlocking with the well-known movement of the warp guide member 103.
Step E (FIG. 3E)
The upper hook 104 makes a half turn to the counterclockwise direction and the weft 2 slides off of the upper hook 104 and slips down and around the outside of the loop of the warp 1 hanging down from the upper hook 104, encircling the outside of the loop. The travelling case receiver 107 begins falling, moving the bobbin case to the left.
Step F (FIG. 3F)
The upper hook 104 makes a half turn to the clockwise direction, looks towards the warp guide member 103 and waits for admission of the lower hook 109. The travelling case receiver 107 falls and transfers the bobbin case 108 to the left-sided stopper 105a of the concave stopper 105a of the case receiver 105 on which the bobbin case 108 was loaded before, and falls further.
Step G (FIG. 3G)
The lower hook 109 advances along the groove arranged on the surface F of the upper hook 104 and hooks the warp 1 from the left side to the right side of the lower hook 109 by means of the well-known movement of the warp guide member 103. The travelling case receiver 107 falls to the position little lower than the bobbin case 108 and then begins travelling to the right.
Step H (FIG. 3H)
The lower hook 109 pulls the loop of the warp 1 out to this side. When the loop of the warp 1 strides across bobbin case 108 finishing travelling to the left, the loop of the warp 1 trips the lower hook 109. The travelling case receiver 107 travels to the right and returns to the starting position. The relation between the warp 1 and the weft 2 at this time is shown in FIG. 3I.
Step I
The warp 1 is pulled backward by means of the fall movement of the well-known falling shaft (not shown), the loop of the warp 1 formed by the lower hook 109 is retracted and the loop of the weft 2 is formed. The upper hook 104 is slanted and the loop of the warp 1 is pulled out of the upper hook 104, and the balanced knot construction is formed as shown in FIG. 4, in which N-shaped loops of the warp 1 and S-shaped loops of the weft 2 twine together. Meshes are fastened by increasing tension, and knots become tight as shown in FIGS. 5A and 5B and the warp 1 and the weft 2 cross each other at a right angle through knots.
Step J
The net is rolled by the well-known net roller (not shown) as long as the length between knots. And the weft 2 linking to the knot at the extreme left is cut from the knot at the prescribed position, the bobbin case 108 linked to this weft 2 is removed from the case receiver 105 and the other bobbin case 108 is loaded afresh on the concave stopper 105a at the right end of new case receiver 105. The tip of the weft 2 of this bobbin case 108 is fixed at the prescribed position until the knot forming step in next net knotting cycle is finished.
As the above mentioned, one cycle of the net knotting step is finished and the cycle is repeated hereafter. Rolling back the net rolled around the roller as foregoing, as shown in FIG. 6, groups of the weft 2 run slantly against groups of the warp 1 running straightly and meet the warp 1 through knots, and the weft 2 travels as much as the pitch of the warp 1 to the left between knots. Unfolding the net, as shown in FIG. 7, groups of warp 1 and those of the weft 2 meet each other at a right angle.
Second Embodiment (Refer FIGS. 8 to 17)
This net knotting machine is of a circular type, and the net is formed in cylindrical shape. Numeral 4 is a guide hook ring which forms a guide hook 10 in pectinate and fixed on the inner circumferential wall of a L-shaped ring 12 on a fixed basic ring 50 set up in an inside support 11. Numeral 5 is an upper hook set up on almost right overhead the guide hook 10 and pivotably supported by a support ring 13. A gear 14 cut in on the support ring 13 is turned by means of a rack ring 15 turning inside said support ring 13. Said support ring 13 is held by a support bracket 71 fixed on an outside support 20. A gear 70 rotated by a motor 69 on said support ring 13 engages with said rack ring 15 and swings on an inside convex edge 79 of the support ring 13. Said upper hook 5 is unable to slant backward and forward, so that a thread hanging portion 16 is bent sidewards so as to be tripped by turning when a knot 3 is pulled out for fastening the mesh. Numeral 17 is a supporting disc of a warp tube 23, on the outer circumference of which a gear 19 engaging with a driving force gear 18 is cut in. The disc rotates on an orbital ring 21 arranged on an outer support 20 and has a circular rod 22 hanging at the middle lower surface thereof. Radially around the rod 22, the warp tubes 23 winding the warp 1 around the tube are supported.
Numeral 24 is a drawing control device of warp 1 and comprises a basic ring 26 having a convex line engageable with a key slot 25 of said circular rod 22, a vertically movable portion 29 composed of an inner ring 27 connected with an outer ring 28 and a fixed ring 30 set by the circular rod 22. A vertical rod 31 connected to said basic ring 26 passes through the disc 17 at a hole 32 and connects to a bar 34 pivoted by a pivot 33 fixed on the disc 17. The other end of said bar 34 connects to a cam 72 and the drawing control device 24 makes prescribed vertical movement rotating with the disc 17. When the vertically movable portion 29 falls, the warp 1 drawn out of the warp tube 23 stops drawing, being caught by the outer ring 28, the fixed ring 30 and the inner ring 27. Numeral 75 is a rotating shaft of the cam 72 and located on the disc 17 with a motor 76 setting a cam 73 and a cam 74 to be described later. Numeral 35 is a warp guide ring actuator and a warp guide member 39 is arranged on the outer circumference of a circular ring 38 connected to a basic ring 37 engaging a key slot 36 of said circular rod 22 with a convex line on the inner surface of the actuator.
Numeral 40 is a vertical rod set on said basic ring 37, which passed through the hole of said disc 17 and connects to a horizontal rod 41 pivoted to said pivot 33. Said horizontal rod 41 connects to said cam 73, and the warp guide member 39 makes required vertical movement, rotating with the disc 17.
Numeral 42 is a mesh fastening device arranged below said guide ring actuator 35. The convex line on a basic ring 43, 44 engages with the key slot 36 of said circular rod 22. A mesh fastening ring 45 connects to the basic ring 43, 44. A vertical rod 62 connected to the basic ring 43 passes through said disc 17 and the upper end of which connects to a horizontal rod 64 connecting to a cam 74, making said pivot 33 as a fulcrum. While the drawing of the wrap 1 is suspended by means of the drawing control device 24, meshes are fastened by making them fall. Respective joining parts 63 between said vertical rods 40, 31, 62 and horizontal rods 41, 34 and 64 are desired to be universal joints.
Numeral 46 is a net sliding ring guiding a net 83, corresponding to the inside of said guiding hook ring 4 and attached to a support rod 68 connected to an unrotatable basic ring 47 engaged and supported to the lower end of said circular rod 22.
Numeral 65 is an inner convex line of said basic ring 47; 66 is an outer circumferential groove of said circular rod 22 and 67 is a ball lain between the inner convex line 65 and the outer circumferential groove 66.
Numeral 8 is a bobbin case housing a bobbin winding the weft 2 and radially arranged on the outer circumference of the guide hook ring 4 loaded on a bobbin case receiver 9, equal in number to the number of the warp tubes 23. Said bobbin case receiver 9 is arranged on said fixed basic ring 50 so as to be oscillated through a roller 51.
Numeral 52 is a L-shaped bar engaged with a connecting ring 53 fixed on said support 11, the upper end of which is pivoted to said bobbin case receiver 9 through a connecting rod 86, and through the lower top of which a connecting ring 77 passes and a connecting rod 54 hangs down at proper spaces. The top of a roller 55 is rolled on a cam 80 rotated by a motor 78, and the bobbin case receiver 9 is travelled back and forth. Numeral 56 is a spring loaded between said L-shaped bar 52 and the fixed basic ring 50; 61 is a thread trip arranged at the tail end of the bobbin case receiver 9 and 84 is a tooth form cut in on the inner circumferential surface of the cam 80.
Numeral 6 is a lower hook drawing out the loop of the warp 1, as shown in FIG. 15, the top of which is bent sideward and attached to the top end of a support rod 57 so as to be overhead said bobbin case 8. Said support rod 57 forms L-shape and engages with a connecting ring 58 fixed to said inner support 11, and the lower end of the support rod 57 is connected to a connecting rod 59 and said lower hook 6 is actuated outward against a spring 87 through a roller 60 rolling on a cam 82 driven by a motor 81. Numeral 85 is a tooth form cut in on the inner circumferential surface of said cam 82. Each of the upper hook 5, the lower hook 6, the bobbin case 8, the bobbin case receiver 9, the warp tube 23, the warp guide member 39, the L-shaped bar 52, the support 57, etc. mentioned above is arranged on each circumference, at equal pitch and in equal number.
The circular net knotting machine is constituted as mentioned above:
The upper hook 5 is turnable in natural and reverse directions by means of the rack ring 15 through the gear 14; the warp guide member 39 is able to travel vertically and turnable in natural and reverse directions around the circular rod 22; the bobbin case 8 is able to swing and guide the weft 2 to the position service able to hang it to the upper hook 5 by the rise of the inner end as well as to trip the loop of the warp 1 hanged to the lower hook 6 when the outher end falls together with the thread trip 61; the upper hook 5 is unable to slant for tripping the loop of knotted thread as like as the upper hook 4 in the first embodiment, however, the upper hook 5 bends to a certain direction at the thread hanging portion 16, so that the loop of the knot can be taken out of the upper hook 5 by swinging the circular ring 38 to the direction, after knotting the thread. Therefore, as same construction of knot as in the first embodiment can be formed in the circular net knitting machine. And, as shown in FIG. 16, after finishing one knot, when the roller 49 is turned to the definite direction as much as an angle equal to the pitch of the warp 1 every time rolling one mesh, the weft 2 is arranged in parallel to the generating line of the cylinder, which the warp 1 is spirally arranged to the cylinder, and that the warp 1 meets the next weft 2 and forms the knot thereof till one knot to another.
Moreover, in the second embodiment, in place of turning the disc 17 one graduation between one knot and another, if the bobbin case is adapted as turning to a certain direction a pitch by pitch, as shown in FIG. 17, the warp 1 is arranged in prallel to the generating line and weft is spirally, arranged, and as same net as shown in the first embodiment can be formed. The cylindrically formed net is cut along the generating line at one spot and then unfolded, the square-meshed net which warp 1 and weft 2 meet each other at a right angle can be attained. | The invention relates to square-meshed net, and method and machine for knotting the same. In knotting a net using upper hooks arranged in a line, warp is arranged in opposition to the upper hooks and knotted to weft by the same upper hook as that in opposition to warp, and weft is transferred in one cycle of the knotting to next upper hook in a prescribed direction and knotted to warp by the next upper hook. In knotting a net using upper hooks arranged in circular form, warp (or weft) is knotted to weft (or warp) by the same upper hook as that in opposition to warp (or weft), and weft (or warp) is transferred in one cycle of the knotting to next upper hook in a prescribed direction and knotted to warp (or weft) by the next upper hook. Warp and weft are perpendicular to each other at the unfolded state and rectangular meshes are constituted. In some case, weft is turned twice and constitutes S-shaped loop. | 3 |
This application claims priority on U.S. Provisional Patent Appl. No. 60/462,559, filed Apr. 10, 2003.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to an apparatus for testing for the presence of trace amounts of a contraband material on the surface of an object.
2. Description of the Related Art
Terrorism risks continue to increase at transportation facilities, government buildings, banks, restaurants, hotels and other locations where there is a significant flow of pedestrian or vehicular traffic.
Airlines now routinely screen passengers and employees for explosives. Screening typically is carried out in several stages. For example, all passages are required to pass through a metal detector and all baggage is required to pass through an X-ray apparatus. However, a plastic explosive device could be concealed on a person or in a piece of luggage in a manner that might not be detected by a conventional metal detector or an X-ray apparatus. Even a small amount of a plastic explosive can cause sufficient damage to bring down an aircraft.
Most airports now include apparatus for detecting trace amounts of explosives. These devices operate on the principle that small amounts of the explosive materials will be transferred to the body, clothing and luggage of people who had handled the explosive. Some detectors employ small flexible fabric-like traps that can be wiped across a package or piece of luggage. The trap removes residue from the surface of the package or luggage. The trap then is placed in an apparatus, such as an ion trap mobility spectrometer, that tests the residue on the trap for trace amounts of explosive materials. A device of this type is disclosed in U.S. Pat. No. 5,491,337 and is marketed by the GE Ion Track. These devices typically are employed in proximity to the metal detectors, and security personnel will perform screening on some of the passengers based on a random sampling or based on a determination that the passenger has met certain criteria for enhanced screening.
The ion trap mobility spectrometer disclosed in U.S. Pat. No. 5,491,337 also can operate in a mode for detecting trace amounts of narcotics. Narcotics are illegal and insidious. Furthermore, it is known that many terrorists organizations fund their terrorism through the lucrative sale of narcotics.
The above-described ion trap mobility spectrometer and similar devices have been accepted at airports in view of the notorious efforts of terrorist groups to attack commercial airliners. The above-described detectors have not been accepted widely at other potential targets of terrorism, including train stations, bus terminals, government buildings and the like. The screening of personnel entering train stations, bus depots, government buildings and such by the above-described detection devices would significantly slow the flow of people into and through such buildings and would impose a significant cost penalty on the operators of such facilities.
Only a fraction of airline passengers have their baggage checked for trace amounts of explosives or narcotics using the available ion trap mobility spectrometers and similar devices. Efforts to use such devices to check all bags for trace amounts of explosives or narcotics would impose greater time and cost penalties on the airline industry. Additionally, explosive detectors typically are used only on luggage and other parcels. An apparatus of this type would not identify plastic explosives worn by a passenger who had no carry-on luggage.
U.S. Pat. No. 6,073,499 discloses a walk-through detector. The detector shown in U.S. Pat. No. 6,073,499 operates under the principle that a boundary layer of air adjacent to a person is heated by the person. This heated air adjacent a person is less dense than air further from the person. Less dense air rises. Accordingly, a thermal plume of air flows up adjacent to a person. Minute particles, including particles of explosives or narcotics, will be entrained in this thermal plume of air and will flow upwardly from a person. The walk-through detector disclosed in U.S. Pat. No. 6,073,499 employs an ion mobility spectrometer or ion trap mobility spectrometer to detect microscopic particles of interest that are likely to be entrained in the thermal plume of air flowing upwardly adjacent to a person who walks through and pauses briefly in the detector. The walk-through detector disclosed in U.S. Pat. No. 6,073,499 is very effective for detecting whether a person is carrying explosives or narcotics and whether the person has recently handled explosives or narcotics.
A person who had handled explosives or narcotics is likely to have microscopic residue of the explosive or narcotic materials on his or her fingers, and trace amounts of the explosive or narcotic will be transferred to objects that are handled by the person. For example, it has been assumed that residue of such contraband will be transferred from the fingers to an airline ticket, a boarding pass or an identification card. Hence, the contraband conceivably could be detected on the ticket, pass or card. Efforts have been made to develop a detector that identifies particles of interest on such a card-like object. One such effort used a fabric-like trap, similar to those used to wipe down luggage. The trap was mounted on a heated metal drum that would be rotated against a surface of the card-like object being tested. These efforts have not proved to be commercially successful because of the potential for damage to the ticket or boarding pass due to heat generated by the detector. The trap could be cooled between tests, but such cooling would add significantly to the cycle time. Additionally the fabric traps were found to soil quickly and hence required frequent changing.
In view of the above, it is an object of the invention to provide an apparatus for testing the surfaces of substantially planar sheet-like materials for the presence of explosives, drugs or other substances of interest.
SUMMARY OF THE INVENTION
The subject invention is directed to a detector with means for detecting explosives, narcotics or other substances of interest. The means for detecting preferably is an ion trap mobility spectrometer, such as the detector disclosed in U.S. Pat. No. 5,491,337, the disclosure of which is incorporated herein by reference. A product of this type is marketed by GE Ion Track under the trademark ITEMIZER 3®. The detector also could be an ion mobility spectrometer, such as the type disclosed in U.S. Pat. No. 5,200,614. Other means for detecting trace amounts of explosives, narcotics or other volatile substances can be employed as the detector in the apparatus of the subject invention.
The detector includes a sampling apparatus with a housing that has a slot for receiving the edge of a thin planar material. For example, the slot may be dimensioned for slidably receiving a passenger boarding pass, ticket, credit card, driver's license, employee ID card, passport or the like. For convenience, these thin objects will be referred to collectively as cards.
The card sampling apparatus includes at least one wiper disposed in the housing and in proximity to the slot. The wiper is dimensioned and configured for wiping across a surface of the card as the card is slid through the slot. The wiping interaction between the card and the wiper is effective for removing materials that may have been deposited on the card and that may be of interest. Two wipers preferably are disposed and configured to engage opposite surfaces of the card so that material is effectively scraped or wiped from both opposed surfaces of the card. The wipers preferably are flexible and preferably are formed from a thin metallic material.
The card sampling apparatus includes a switch and/or sensor that is operative to sense that the card has passed completely through the slot. The switch or sensor is operatively connected to an electromechanical device, such as a solenoid, that closes a chamber around the wiper after the card has passed through the slot. The wiper then is heated sufficiently to vaporize and desorb the sampled material on the wiper. The heating may be achieved by applying a voltage across the wiper and thus causing the wiper to heat to approximately 240° C. An airflow then is generated to transfer the desorbed sampled material from the chamber and into the above-described detecting means for analysis. The passage for generating the airflow preferably is heated for delivering air from the chamber at an elevated temperature. The chamber around the wiper preferably remains closed during the analysis.
The apparatus may further include means for displaying the results of the analysis. The displaying means may include a monitor, a printer and/or an audible signal generator.
The apparatus operates the solenoid or other electromechanical apparatus for opening the chamber upon completion of the analysis and for placing the apparatus in a condition for a subsequent sampling.
The apparatus of the subject invention offers several significant advantages. First, the apparatus does not require the time consuming and labor intensive task of rubbing the filter or trap across a surface to be tested, mounting a fabric-like trap or filter into a detector and then waiting for the test results before the tested luggage or parcel can be returned to the customer.
The apparatus also has a desirably short cycle time, preferably in the range of 3-5 seconds. This short cycle time is partly attributable to the use of the thin metallic wiper that can be heated very quickly and then cooled very quickly and partly due to the heating of the air drawn from the chamber. Additionally, the wiper functions to collect and concentrate a sample at the leading edge of the wiper. In contrast, known devices that employ fabric-like traps or filters spread a sample out over the surface. Hence, vaporization of a sample and desorbtion from the edges of the wipers is faster and more complete.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a detector that incorporates the apparatus of the subject invention.
FIG. 2 is a schematic view of an ion trap mobility spectrometer of the detector shown in FIG. 1
FIG. 3 is a front elevational view of the card sampling apparatus separated from the detector.
FIG. 4 is a side elevational view of the apparatus.
FIG. 5 is a rear perspective view of the apparatus.
FIG. 6 is an exploded elevational view of the apparatus with the outer housing removed.
FIG. 7 is an exploded top plan view of the apparatus shown in FIG. 6 .
FIG. 8 is an elevational view of the portion of the apparatus shown in FIGS. 6 and 7 in a fully assembled condition and with the enclosure in an open ready-to-use position.
FIG. 9 is an elevational view similar to FIG. 8 , but showing the enclosure in the closed position.
FIG. 10 is a perspective view of the stationary shell of the enclosure.
FIG. 11 is a perspective view of the movable shell of the enclosure.
FIG. 12 is a perspective view of the wiper support.
FIG. 13 is a perspective view of the wiper.
FIGS. 14 and 14A are perspective views of the apparatus with the outer housing removed.
FIG. 15 is a perspective view similar to FIG. 14 , but having one enclosure and one wiper removed.
FIGS. 16 and 17 are perspective views showing structure for delivering heated air to the ion trap mobility spectrometer.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A detector according to the invention is identified generally by the numeral 10 in FIG. 1 . The detector 10 includes an outer housing 11 and a flat panel display monitor 12 such as an LCD monitor. An ion trap mobility spectrometer (ITMS) is disposed within the housing 11 and is illustrated schematically in FIG. 2 .
The ITMS of FIG. 2 comprises a cylindrical detector 20 having an inlet 22 at one end for receiving sample air of interest borne by a carrier gas which that has been doped with a low concentration vapor (typically a few parts per million) employed as a charge transfer mediator. More particularly, the inlet 22 communicates with a source of sample air of interest 14 and a supply of carrier gas and dopant 16 with flows of gases to the inlet 22 being enabled by a flow generator such as a pump illustrated schematically and identified by the numeral 18 in FIG. 2 . A heated membrane 19 formed from a microporeous refractory material or from dimethyl silicone is disposed near the inlet 22 and in communication with the source of the sample of air 14 for blocking passage of at least selected constituents of the air and for enabling passage of other constituents of the air, including the constituents of interest. The sample air, carrier gas, and dopant molecules pass through the inlet 22 and are spread by a diffuser 24 into an ionization chamber 26 . The ionization chamber 26 is in the form of a shallow cylinder with a diameter D, length L, and cylindrical wall 28 of a radioactive material, e.g., nickel 63 or tritium, which emits beta particles. Inlet 22 communicates with one end of the ionization chamber 26 . A grid electrode E 1 is provided at the end opposite the inlet 22 , and is normally maintained at the same potential as the inlet end and the walls of the ionization chamber 26 . Thus a largely field-free space is provided in which electrons and ion charges build up and interact with the sample molecules under bombardment by the beta-particles from the radioactive walls. Beyond the ionization chamber 26 , the ionized sample gases pass through open electrode E 1 and into an ion drift region 30 having several field-defining electrodes E 2 -E n . A collector electrode or plate 32 is disposed at the end of the drift region 30 for receiving the ion samples reaching that end.
Periodically a field is established across the ionization region 26 , by creating a potential difference between the grid electrode E 1 and the inlet diffuser 24 and radioactive source 28 , for about 0.1-0.2 mS, to sweep the ions through the open grid E 1 into the drift region 30 with the assistance of the switching of the field between electrodes E 1 and E 2 . The ions in the drift region 30 experience a constant electric field, maintained by the annular electrodes E 2 -E n , impelling them along the region and down toward the collector electrode 32 . The electrode 32 detects the arriving charge, and produces signals that are amplified and analyzed through their spectra in the spectrometer. The gases exit through an outlet in the wall next to the electrode 32 . After about 0.2 mS the field across the ionization region 26 is again reduced to zero and the ion population is again allowed to build up in the chamber 26 preparatory to the imposition of the next field. The polarity of the fields is chosen on the basis of whether the detector is operated in a negative or positive ion mode. When detecting explosives, a negative ion mode is usually appropriate, but when detecting narcotic samples positive ion mode is preferred.
The card sampling apparatus of the detector 10 is identified generally by the numeral 40 in FIGS. 1 and 3 - 15 . The card sampling apparatus 40 includes a housing 42 with a slot 44 . The slot 44 has a wide top and a narrow intermediate section. The wide top of the slot 44 facilitates the guided entry of a card 46 into the slot 44 . The slot 44 defines a depth sufficient to accommodate a major portion of the width of the card 46 . Arrows 48 are embossed or imprinted prominently on the housing 42 near the slot 44 to indicate the direction for moving the card 46 through the slot 44 . The card 46 is depicted to resemble a credit card, an identification card or a driver's license. However, the apparatus 40 can be used with any other thin object, such as a passenger ticket, a boarding pass, a theater ticket or the like.
The card sampling apparatus 40 includes an enclosure identified generally by the numeral 50 in FIGS. 6-9 . The enclosure 50 includes a stationary shell 52 and a movable shell 54 . The stationary shell 52 is formed with a linear array of protrusions 53 and with an air passage 55 , as shown in FIG. 10 . The stationary shell 52 is mounted fixedly in the housing 42 . The movable shell 54 is shown in FIG. 11 , and is mountable to a solenoid for selective movement toward and away from the stationary shell 52 . More particularly, the movable shell 54 is spaced slightly from the stationary shell 52 in the open position shown in FIG. 8 , but is engaged sealingly with the stationary shell 52 in the closed condition shown in FIG. 9 .
The card sampling apparatus further includes a wiper support 56 as shown in FIG. 12 . The wiper support 56 is mounted to the stationary shell 52 . The wiper support 56 includes an elongate recess with a linear array of protrusions 58 substantially identical to the protrusions 53 on the stationary shell 52 .
The card sampling apparatus 40 further includes two substantially identical wipers 60 , as shown in FIG. 13 . A first of the first wipers 60 is mounted to the stationary shell 52 and a second of the wipers 60 is mounted to the wiper support 56 , which in turn is mounted to the stationary shell 52 . Each wiper 60 is formed from a spring tempered electrically conductive material, such as stainless steel sheet or foil, with a thickness of about 0.002-0.004 inch, and preferably about 0.003 inch. Each wiper 60 has a wiping blade 62 which terminates in a substantially linear wiping edge 64 . Thin parallel spring arms 66 extend perpendicularly from the wiping blade 62 . The spring arms 66 are disposed and dimensioned such that the distance between adjacent arms 66 exceeds the width of each arm 66 . Thus, each wiper 60 has a very low thermal mass, and can heat and cool very quickly. Each spring arm 66 has a mounting end 68 remote from the wiping blade 62 . The spring arms 66 at the ends of the wipers 60 have large apertures 70 in the mounting end 68 for receiving screws to mount the respective wiper 60 to the stationary shell 52 or the wiper support 56 . All other spring arms 66 have smaller crenulated apertures 72 for force fit engagement onto the protrusions 53 on the stationary shell 52 or the protrusions 58 on the wiper support 56 . The spring arms 66 each include a bend 74 between the blade 62 and the mounting ends 68 .
A first of the wipers 60 is mounted to the stationary shell 52 by passing screws through the large apertures 70 and into threaded holes in stationary shell 52 and by forcing the small crenulated apertures 72 onto the protrusions 53 . A second of the wipers 60 is mounted to the wiper support 56 in a similar manner. The wiper support 56 then is mounted to the stationary shell 52 by screws. As a result, the opposed wipers 60 are juxtaposed so that the wiping edges 64 are parallel and preloaded against one another. In the illustrated embodiment, the wiping blades 62 and adjacent parts of the spring arms 66 of the opposed wipers 60 define a V-shape that points in the direction of movement of the card.
The subassembly of the stationary shell 52 the wiper support 56 and the wipers 60 are mounted to a support 76 in the card sampling apparatus 40 so that the abutting edges 64 of the wipers 60 are aligned perpendicular to the direction of movement of the card 46 through the slot 44 . Additionally, V-shape defined by the wipers 60 points in the card insertion direction. The movable shell 54 then is mounted to oppose the stationary shell 52 . In other embodiments, the wipers may define oppositely directed Ω shapes so that the card can be slid in either direction.
The card sampling apparatus 40 further includes terminals 78 on the stationary shell 52 and on the wiper support 56 . The terminals 78 are connected to wires (not shown) and are operative for delivering an electric current to the wipers 60 for rapidly heating the wipers 60 .
The card sampling apparatus 40 further includes sensors 80 for detecting when a card 46 has passed through the slot 44 . Additionally, the card sampling apparatus 40 also includes an outlet 82 as shown in FIG. 5 . A stainless steel tube 84 extends between the outlet 82 and the enclosure 50 . The end of the tube 84 remote from the outlet 82 passes into the stationary shell 52 and is capped by a conductive cap 86 , as shown in FIGS. 16 and 17 . The cap 86 is held in place by a set screw 88 . The tube 84 includes a transverse hole 90 as shown in FIG. 17 . The hole 90 communicates with the air passage 55 in the stationary shell 52 , and hence lets air flow from the enclosure 50 to the tube 84 and then to the outlet 82 so that the desorbed sample can be delivered between the enclosure 50 and the inlet 22 of the ITMS shown in FIG. 2 . A terminal 92 is connected to the outlet 82 , and a terminal 94 is connected to the cap 86 . Wires connected to the terminals 92 and 94 apply a voltage that enables the stainless steel tube 84 to be heated to about 160° C. for heating the air flowing between the enclosure 50 and the outlet 82 . Furthermore, the card sampling apparatus 40 includes an electrical connector 96 for connecting the card sampling apparatus 40 to a controller (not shown) mounted in the detector 10 for controlling the closing of the enclosure 50 after passage of the card 46 and for controlling the heating of the wipers 60 when the enclosure 50 is closed.
The detector 10 is employed by merely swiping a card 46 through the slot 44 in the card sampling apparatus 40 . The movement of the card 46 through the slot 44 causes the card 46 to move between the wiping edges 64 of the wipers 60 . Hence, the spring arms 66 deflect about the respective bends 74 . The spring tempered metallic material of the wipers 60 will cause the wiping blades 62 to exert a biasing force against opposite side surfaces of the card 46 . The spaces between the spring arms 66 are sufficiently large and the spring arms 66 are sufficiently thin to require only a minor force to pass the card 46 between the biased wiping blades 62 of the wipers 60 . However, the resiliency of the spring metal will exert a sufficient force for keeping the wiping edges 64 in contact with the opposed side surfaces of the card 46 .
The sensors 80 will sense when the card 46 has completed passing through the slot 44 . Hence, the signal generated by the sensors 80 will cause the controller to move the movable shell 54 toward the stationary shell 52 and into the closed position around the wipers 60 , as shown in FIG. 9 . Current then will be applied to the terminals 78 for heating the wipers 60 to a temperature of approximately 240° C. This heating can be carried out very quickly in view of the relatively small thickness (e.g. 0.003 inch) of the wipers 60 . Additionally the spaces between the spring arms 66 reduce the thermal mass of metal material that must be heated, and hence contribute to very rapid heating of the wipers 60 . The heating vaporizes and desorbs material collected on the wiping edges 64 of the wipers 60 . Simultaneously, the ITMS illustrated in FIG. 2 is actuated to draw air and potential vaporized particles of interest through the air passage 55 and into the inlet 22 , both of which are heated. The ITMS then is operated in the manner described above and in U.S. Pat. No. 5,491,337 to identify any minute amounts of substances of interest that will have been wiped from the card 46 by the wipers 60 . The results of the analysis will be displayed on the monitor 12 . The cycle time between the initial swiping of the card 46 through the slot 44 to the display of the test results on the monitor 12 is likely to be approximately 3-4 seconds.
The low thermal mass of the wipers 62 and 64 ensures that the wipers will cool quickly after termination of the electric current and the opening of the enclosure 50 . Hence the wipers will be at a sufficiently low temperature to prevent damage to a card 46 during a subsequent cycle.
The rapid cycle time and high efficiency of the detector 10 is partly attributable to the concentration of sample material on the edges 64 of the wipers 60 . More particularly, conventional detectors employ a soft fabric-like filter or trap material, and samples are collected across a relatively large surface area of the material. Subsequent desorbtion or vaporization of the sample is slower and less complete. In contrast, the concentration of the samples on the thin edges 64 of the wiper 60 is well suited to rapid desorbtion/vaporization and achieves a very high efficiency and accuracy.
The invention has been described with respect to a preferred embodiment. However, variations will be apparent to a person skilled in the art after having read the subject disclosure. For example, the invention has been depicted with respect to a stand-alone dedicated apparatus for detecting the presence of substances of interest on the card. However, the apparatus can be incorporated into a multifunction device. For example, the apparatus can be incorporated into an e-ticket machine common at airport terminals or into a boarding pass scanning machine, common at many boarding gates. Thus, any apparatus that receives and processes a card for some other purpose can be adapted to include the apparatus of the subject invention. Additionally, the apparatus has been described as being used with an ion trap mobility spectrometer. However, other devices are known for identifying particular substances of interest, and any such devices can be employed with the subject invention. | A device is provided for testing surfaces of a card for the presence of explosives, drugs or other substances of interest. The device includes a slot for receiving the card. Thin metallic wiper blades are dispose in alignment with the slot and wipe over surfaces of the card as the card is passed through the slot. Thus, substances on the surface of the card are transferred to the wiper blade. The wiper blade then is enclosed and rapidly heated to desorb the material retrieved from the card. The enclosure then is placed in communication with a detector to test for the presence of substances of interest. | 6 |
This application is a Continuation of application Ser. No. 122,687, filed on Nov. 18, 1987, now abandoned.
BACK GROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a viscous fluid coupling devices, and more particularly to such coupling devices which transmit torque as a function of the temperature of an associated fluid. More particularly still, the present invention relates to temperature sensitive viscous fluid coupling devices which can control the transmission of the output torque in accordance with temperature, which are employed as vehicle fan devices and which are actuated as a function of temperture.
2. Description of Prior Art
A conventional viscous fluid coupling device is disclosed, for example, in U.S. Pat. No. 3,227,254 to Sutaruk. Such a viscous fluid coupling device is generally comprised of a pulley which is fixed for rotation with a coupling input shaft and supported on the engine. The pulley is adapted to be driven preferably by a belt from the vehicle crankshaft. The coupling input shaft is fixed for rotation with a driving clutch or coupling member and a coupling housing member is mounted for rotation on the input shaft by suitable bearing means. The coupling housing member substantially encloses the driving clutch or coupling member and is adapted to be driven by the driving clutch member through the shear of viscous fluid disposed in the housing. A combination cover and fluid storage assembly means is fixed for rotation with the housing member and is formed by spaced plate portions which define a fluid storage chamber axially adjacent the shear surfaces on the driving clutch member and the coupling body member, respectively.
A valve structure for controlling the flow of fluid from the storage or reservoir chamber to the operating chamber according to the prior art is shown in FIG. 2 and is comprised of an inlet opening disposed formed in the valve plate and a thermostatically operated valve arm which is selectively movable to various positions to completely cover, partially or completely uncover the valve inlet opening. This invention is directed to the disposition and configuration of the inlet valve opening so that the volume of fluid admitted to the viscous coupling or clutch.
A thermostatic means is mounted on the cover plate for positioning the valve arm with respect to the inlet opening. A discharge valve means or opening is disposed or formed in the valve plate and cooperates with a pumping means to evacuate fluid from the operating chamber to the reservoir chamber.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a new means for regulating the volume of fluid in an operating chamber of a shifting coupling to thereby control the power transmitted from the driving member to the driven member.
A further object is to regulate the volume of the fluid in the operating chamber by means of which is operative responsive to the temperature of the air surrounding viscous fluid coupling.
Another object is to regulate an opening between the reservoir and the operating chamber and means to vary the effective the radial distance of the opening from the axis of rotation of the clutch assembly.
These and other object and advantage of the invention will appear from the following description taken with the drawings showing in this part of the specification.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a sectional view of one embodiment of a viscous fluid coupling device in accordance with the present invention.
FIG. 2 shows a modification of a valve assembly in accordance with a prior art.
FIG. 3 is a graphical illustration of rotation speed of the output members versus fluid volume in the operating chamber of the embodiment of FIG. 1.
FIG. 4 is a graphical illustration of rotation speed of the output members versus temperature at the front of temperature sensor of FIG. 1.
FIG. 5 shows the modification of the valve assembly in accordance with present invention.
FIG. 6 is a hysteresis curve of rotation speed of the output members versus temperature at the front of temperature sensor of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
A viscous fluid coupling device constructed in accordance with a preferred embodiment of the present invention will be described with reference to the drawings.
Referring particularly to FIG. 1 of the drawings, a viscous fluid coupling device of the present invention includes a rotor 10 fixed to a input shaft 11 which is arranged as an input member to be driven by a engine (not shown). The rotor 10 has annular projections 10a which are integrally formed with the face of the outer peripheral portion of the rotor 10. The rotor 10 is accommodated in output members 12 and 13. The output members 12 and 13 which are rotatably mounted in a fluid-tight manner on the input shaft 11. The output member 12 is rotatably mounted in a fluid-tight manner on a neck portion of the input shaft 11 by means of sealed ball bearing means 11a. The output member 12 is integrally formed at its inner wall with a set of annular projections 12a which are coupled with the annular projections 10a of rotor 10 to provide a labyrinth L. The housing assembly 40 further includes the output member 12 which is secured in a fluid-tight manner to an opening end of output member 13 through an annular seal member 30. A circular partition wall member 15 is coupled with an annular stepped portion of the output member 13 and secured in place to divide the interior of housing assembly 40 into an operation chamber 17 and a reserver chamber 16. The operation chamber 17 accommodates therein the rotor 10 and a portion of the viscous fluid, while the reservoir chamber 16 stores therein the remaining portion of viscous fluid. On the wall of the rotor 10, a viscous fluid circulation passageway 14 is formed.
The output member 13 is provided at its outer peripheral portion with a pumping mechanism 18. The pumping mechanism 18 feeds the viscous fluid from the operation chamber 17 to the reservoir chamber 16 with pressure. Labyrinth transmitting surface 19 is between the rotor 10 and the output member 12. Passageway 14 leads to torque transmitting surface 19. The slot 20 is formed on the partition wall 15 to supply the viscous fluid from reservoir chamber 16 to operation chamber 17. A non-perforate valve member 22 which controls the opening and closing of slot 20 is rotated on the partition wall 15 by temperature sensitive member 21. The slot 20 and the valve member 22 cooperate to form a opening area 24 when they are in a certain relation. When a spiral bimetal is used as the temperature sensitive member 21, one end thereof is fixed at output member 13 and the other end is fixed to a freely rotatable rod 23 to rotate the valve member 22. For example, the temperature sensitive member 21 comprises a bimetal or a shape memory alloy.
In this embodiment, the slot 20 is formed on an outer circumference of the partition wall 15, as shown FIG. 5. The shape of the slot 20 is substantially trapezoidal and has a concave edge which has a gentle inclination with respect to the radial direction. When the temperature of the air surrounding the viscous fluid coupling device is low, that is, when the valve member 22 is in the position shown in FIG. 5(a), the opening area 24 is not formed, and the valve member 22 blocks the slot 20.
When the temperature sensitive member 21 senses the rise of the temperature rise at a low temperature and rotates the valve member 22 to the position, as shown FIGURE 5 (b), the outer edge of the valve member 22 forms the opening area 24. Since the slot 20 has the concave slope edge 42, the increase rate of the opening area 24 becomes lower at a low temperature region. When the temperature of the air surrounding the viscous fluid coupling devices reaches high temperature region, the increase rate of opening area 24 becomes large. FIG. 5 (c) is the state in which the slot 20 is at a high temperature.
When the viscous fluid coupling device having the above mentioned valve structure is used as a device to drive the cooling fan of the engine cooling system, a rotational speed of the cooling fan proportional to the increase in the ambient temperature can be obtained as shown by the dotted line in FIG. 4. In FIG. 6 shows a hysteresis curve of a rotational speed of the cooling fan of the engine cooling system, a rotational speed of the output members to the increase in the ambient temperature. This embodiment is just one example and it is possible to otherwise properly select the shape of the slot and valve member within the range of technological concept of this invention, for example, by making the shape of the slot of another shape equivalent to that of the slot 20 in the partition wall 15 in the aforementioned embodiment.
It should be understood that, although the preferred embodiment of the present invention has been described herein in considerable detail, certain modifications, changes, and adaptations may be made by those skilled in the art and that it is hereby intended to cover all modifications, changes and adaptations thereof falling within the scope of the appended claims. | A viscous fluid coupling device especially is used for driving the cooling fan of engines and for controlling the rotation speed of the fan smoothly according to the temperature. The smooth change of torque transmission by the coupling device is performed by employing a specially shaped slot for fluid passageway. The increase rate of the opening area of the slot is smaller in a low temperature region than in a high temperature region. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to, and hereby incorporates by reference, U.S. Provisional Application No. 60/537,112, entitled “A Proposal for Mobile EMV Transaction,” filed on Jan. 16, 2004, with the U.S. Patent and Trademark Office.
FIELD OF THE INVENTION
[0002] The invention is related generally to secure credit transaction standards, and particularly to the use of such standards in a mobile terminal.
BACKGROUND
[0003] EMV is a payment system specification for credit/debit chip cards and devices designed to perform credit/debit transactions using these chip cards. The EMV specification was jointly developed and maintained by Europay International, Mastercard International, and Visa International (hence, “EMV”). The stated purpose of the EMV specification is to ensure worldwide interoperability between the chip cards and any terminal used in the credit/debit transactions. Compared to magnetic-stripe based credit/data card transactions, EMV is considered by most people to be a more secure payment system. For more information regarding the EMV specification, the reader is referred to EMV 2000 Book 1 from EMVco.
[0004] In a typical EMV transaction, there are mainly three parties involved: a buyer or user who is the cardholder, a merchant, and a bank or other financial institution that is the EMV issuer. Briefly, the buyer initiates the EMV transaction by inserting an EMV compliant chip card (or a device that uses the chip card) into an EMV payment terminal at the merchant. The payment terminal may be, for example, a Point of Sale (POS) terminal equipped with a chip card-reader and EMV access software. This payment terminal obtains the user and chip card information and sends the information to the EMV issuer to be processed. The EMV issuer processes the information and completes the EMV transaction by crediting the merchant and debiting the buyer's account accordingly. Such a transaction is called a “local” or “local environment” transaction because there is no direct connection between the chip card and the EMV issuer.
[0005] But the market uptake for the EMV specification has been fairly low. This is due, in part, to the reluctance of merchants and their POS terminal suppliers to upgrade their software and hardware infrastructure to support EMV. Recently, however, Visa Europe and Mastercard Europe have announced that beginning in January 2005, liability for transactions will shift from the card issuer to the merchant. This means that any party not EMV compliant after January 2005 will bear the liability for fraudulent transactions passing through their system that otherwise could have been prevented had EMV been supported. It is expected, therefore, that there will soon be a dramatic increase in support by merchants and POS suppliers for the EMV specification.
[0006] One way to increase market penetration for the EMV specification is to enable more devices to conduct EMV transactions. Mobile terminals in particular may help facilitate acceptance of the EMV specification because of their widespread usage and convenience factor. Examples of mobile terminals include smart-cards, mobile phones, personal digital assistants, laptop computers, and the like. Unfortunately, the currently existing EMV payment protocol was designed for use primarily in “card present” situations, such as with a card-reader. There have been attempts by various standards bodies to modify the existing EMV specification for local mobile payment transactions, but these attempts have met with little market acceptance because either the methods were cumbersome or they made little business sense.
SUMMARY OF THE INVENTION
[0007] The invention is directed to a method and system for enabling a mobile terminal to conduct an EMV transaction. The method and system of the invention includes a wireless access node in the EMV card-reader terminal for connecting a mobile terminal to the card-reader terminal. An EMV-proxy module executing in the card-reader terminal facilitates communication between the mobile terminal and the card-reader terminal. The EMV-proxy module lets the mobile terminal function in essentially the same way as a regular EMV chip card with respect to the card-reader terminal. The card-reader terminal may then conduct EMV transactions on behalf of the mobile terminal without requiring new software and/or hardware at the EMV issuer. EMV data is stored in the mobile terminal in the form of secure dynamic data objects.
[0008] In general, in one aspect, the invention is directed to a method of conducting an electronic transaction in a card-reader terminal using a mobile terminal. The method comprises the steps of establishing a wireless connection between the mobile terminal and the card-reader terminal and transferring transaction data between the mobile terminal and the card-reader terminal over the wireless connection. The method further comprises the step of hosting a proxy in the card-reader terminal to act on behalf of the mobile terminal, wherein the proxy uses the transaction data to conduct the electronic transaction on behalf of the mobile terminal.
[0009] In general, in another aspect, the invention is directed to a card-reader terminal configured to conduct an electronic transaction with a mobile terminal. The card-reader terminal comprises a wireless access node for establishing a wireless connection between the mobile terminal and the card-reader terminal, a storage unit configured to store computer readable code thereon, the computer readable code including a proxy for the mobile terminal, and a microprocessor connected to storage unit, the microprocessor capable of executing the proxy on the card-reader terminal. The proxy is configured to transfer transaction data between the mobile terminal and the card-reader terminal over the wireless connection and use the transaction data to conduct the electronic transaction on behalf of the mobile terminal.
[0010] It should be emphasized that the term comprises/comprising, when used in this specification, is taken to specify the presence of stated features, integers, steps, or components, but does not preclude the presence or addition of one or more other features, integers, steps, components, or groups thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The foregoing and other advantages of the invention will become apparent from the following detailed description and upon reference to the drawings, wherein:
[0012] FIG. 1 illustrates a model 100 of an exemplary EMV implementation according to embodiments of the invention;
[0013] FIG. 2 illustrates an exemplary data object according to embodiments of the invention;
[0014] FIG. 3 illustrates a flow chart for a regular EMV transaction that may also be used for the EMV transaction according to embodiments of the invention; and
[0015] FIGS. 4A-4C illustrate a timing diagram for an exemplary EMV transaction according to embodiments of the invention.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0016] Embodiments of the invention provide a system and method for enabling a mobile terminal to conduct an EMV transaction. Such mobile terminals will be referred to hereinafter as personal trusted device (PTD) and may include smart-cards, mobile phones, personal digital assistants, laptop computers, and the like. In addition, EMV transactions using a personal trusted device according to embodiments of the invention will be referred to hereinafter as mobile-EMV, whereas EMV transactions involving regular integrated chip cards (ICC) will be referred to hereinafter as ICC-EMV. Also, the software and/or hardware used by the card issuer banks or other financial institution to process the EMV transactions will be referred to hereinafter as the EMV issuer back office.
[0017] FIG. 1 shows a conceptual model 100 of one exemplary EMV implementation according to embodiments of the invention. The model 100 includes an EMV card-reader terminal 102 that is connected to and communicates with an EMV issuer back office 104 over an EMV interface 106 . The EMV issuer back office 104 , the EMV interface 106 , and the various support structures therefor are well-known to persons having ordinary skill in the art and will not be described here. The EMV card-reader terminal 102 , on the other hand, is a new EMV card-reader terminal 102 that is capable of handling both regular ICC-EMV transactions as well as new mobile-EMV transactions. To this end, the EMV card-reader terminal 102 includes well-known data processing and program execution capability as well as data and program storage capability (e.g., microprocessors, memory, storage unit, display, input/output unit, etc.).
[0018] To handle the regular ICC-EMV transactions, the EMV card-reader terminal 102 is equipped with a physical card-reader (not expressly shown) and an EMV access module 108 for operating the physical card-reader. The physical card-reader basically provides a hardware interface (i.e., a physical connection) between the EMV card-reader terminal 102 and an EMV chip card 110 . The EMV access module 108 , on the other hand, executes the data transfer protocol (i.e., an electronic handshake) between the EMV chip card 110 and the EMV card-reader terminal 102 . The physical card-reader and the EMV access module 108 are both well-known to persons having ordinary skill in the art and will not be described here.
[0019] To handle the new mobile-EMV transactions, in accordance with embodiments invention, the EMV card-reader terminal 102 is further equipped with a wireless access node 112 and an EMV-proxy module 114 . The wireless access node 112 basically provides an air interface 116 between a personal trusted device 118 and the EMV card-reader terminal 102 . The EMV-proxy module 114 executes the data transfer protocol between the personal trusted device 118 and the EMV card-reader terminal 102 . In some embodiments, the wireless access node 112 may be a secure short-range wireless access node 112 that is based on, for example, the Bluetooth wireless protocol. For more information regarding the Bluetooth wireless protocol, the reader is referred to www.bluetooth.com. Other types of wireless interfaces (e.g., infrared (IR), near field communications (NFC)) may also be used without departing from the scope of the invention.
[0020] Both the EMV access module 108 and the EMV-proxy module 114 are linked to an EMV terminal module 120 running in the EMV card-reader terminal 102 . The function of the EMV terminal module 120 is to implement the EMV specification that controls how an EMV transaction is conducted. Thus, for example, the EMV terminal module 120 may request certain types of data from the personal trusted device 118 or the EMV chip card 110 that are needed to conduct the EMV transaction, such as user identification, payment authorization, and the like. Since the EMV terminal module 120 does not need to know which communication protocol the personal trusted device 118 or the EMV chip card 110 is using, the actual exchange of data between the EMV terminal module 120 and the personal trusted device 118 or the EMV chip card 110 may be carried out through the EMV-proxy module 114 and the EMV access module 108 using any suitable protocol. The data obtained by the EMV terminal module 120 is then forwarded to the EMV issuer back office 104 over the EMV interface 106 to complete the EMV transaction. In this way, no change is needed in the EMV issuer back office 104 to accommodate the personal trusted device 118 and, hence, the existing EMV issuer back office 104 software/hardware may be preserved. In some embodiments, however, some changes may be made to the EMV issuer back office 104 in order to optimize the EMV transaction.
[0021] Note that, although the EMV access module 108 , the EMV-proxy module 114 , and the EMV terminal module 120 are shown here as separate modules, persons having ordinary skill in the art will understand that all three modules may be combined into a single software package running on the EMV card-reader terminal 102 .
[0022] As mentioned above, one of the tasks of the EMV-proxy module 114 is to execute the communication protocol between the personal trusted device 118 and the EMV card-reader terminal 102 . One aspect of this task is to ensure user authentication. That is, the EMV-proxy module 114 should be able to verify that the identification provided by the user matches the identification stored in the personal trusted device 118 . Preferably, the communication protocol executed by the EMV-proxy module 114 has one or more functions built-in specifically for verifying the identity of the user. An example of such a communication protocol is the Mobile electronic Transaction (MeT) standard promulgated by MeT Limited (www.mobiletransactions.org). Specifically, the MeT standard has several core authorization functions, including the WMLScript, the ECMAScript, and the crypto signTexto functions. For more information regarding the MeT standard, the reader is referred to latest version of the MeT Core Specification from MeT Limited. In accordance with embodiments of the invention, the EMV-proxy module 114 may employ these well-known authorization functions to authenticate the user as well as to capture payment authorization.
[0023] Another aspect of the EMV-proxy module 114 is to ensure security for user data because once the user is verified, confidential user data may be transferred between the personal trusted device 118 and the EMV-proxy module 114 . In some embodiments, security for the confidential user data may be accomplished by using secure data objects to transfer the data. Preferably, the data objects are dynamic so that the data may be modified as needed in accordance with the EMV specification. An example of such a secure dynamic data 204 object is the MeT-ticket used in the MeT Ticketing Secure Handling Framework, as specified in the MeT Ticketing Specification from MeT Limited. In accordance with embodiments of the invention, the EMV-proxy module 114 may employ these well-known MeT-tickets to transfer confidential user data between the personal trusted device 118 and the EMV-proxy module 114 .
[0024] Note that it is not necessary to verify the identity of the EMV card-reader terminal 102 , since the terminal 102 is designed to be tamper-resistant and is therefore implicitly trusted by the EMV issuer back office 104 . It is recommended, however, that the identity of the EMV-proxy module 114 should at least be verified before transferring confidential user data thereto. In some embodiments, the identity of the EMV-proxy module 114 may be verified by setting up a WTLS/TLS Class 2 connection. Then, after successful authentication of both the user and the EMV-proxy module 114 , the EMV-proxy module 114 can initiate a normal EMV transaction with the merchant (EMV card-reader terminal 102 ) and the EMV issuer on behalf of the user.
[0025] In order for the EMV issuer back office 104 to process any EMV transaction, a cardholder account must first be created. Creation of the cardholder account involves the following steps: generation and provisioning of an EMV service certificate, generation and provisioning of an EMV-ticket 200 , and generation and provisioning of EMV symmetric key. These steps are described below with regard to how they are presently performed in the ICC-EMV in order to explain how they may be performed in the mobile-EMV.
[0026] With respect to the generating and provisioning of the EMV service certificate, in some embodiments, the generation and provisioning of the EMV service certificate may be accomplished using a process similar to the MeT certificate registration process, described in the MeT Core Specification. The service certificate, or a URL of the service certificate, may then be stored in the personal trusted device 118 . For more information regarding the process of setting up an MeT service certificate, the reader is referred to the MeT CUE Specification from MeT Limited.
[0027] Generation and provisioning of the EMV-ticket 200 can be accomplished as follows. Regular integrated chip cards 110 store certain items off user-specific data, part of which is static data 202 that is signed as well as unsigned, and part of which is dynamic data 204 that is updated during an EMV transaction. In mobile-EMV, this data may be stored in a secure data object in the personal trusted device 118 . In some embodiments, the data object may be an electronic ticket, such as an EMV-ticket 200 . The EMV-ticket 200 is issued by the EMV issuer and may be securely provisioned in the personal trusted device 118 . The provisioning may be achieved by a physical interface, or it may be done over an air interface 116 . As mentioned above, the EMV-ticket 200 may be an MeT-ticket that conforms to the MeT Ticketing Specification from MeT Limited. The ticketing framework for secure handling of stored data objects, including copy protection against both malicious personal trusted device 118 owners and third party eavesdroppers, may be the MeT Ticketing Secure Handling Framework currently being developed by MeT Limited.
[0028] Other implementations of a secure ticket handling system may also be used, such as the ones described in U.S. patent application Ser. No. 10/008,174, entitled “A Proposal for Secure Handling for Stored Value Electronic Tickets,” by Nils Rydbeck and Santanu Dutta, filed Nov. 13, 2001, and Continuation-in-Part application Ser. No. 10/103,502 by Santanu Dutta, filed Mar. 21, 2002. Both of these applications are incorporated herein by reference.
[0029] FIG. 2 illustrates the data structure of an EMV-ticket 200 according embodiments of the invention. Such an EMV-ticket 200 may be generated by the EMV issuer and transferred to the personal trusted device 118 at the time of cardholder account creation/registration. As can be seen, the EMV-ticket 200 data structure includes signed static data 202 , unsigned dynamic data 204 , and unsigned EMV data 206 . In some embodiments, the unsigned dynamic data 204 in the EMV-ticket 200 may be optional. In most embodiments, the unsigned EMV data 206 is mandatory.
[0030] With respect to the signed static data 202 , by way of explanation, in ICC-EMV, static data 202 authentication is performed by the card-reader terminal 102 . The static data 202 is signed by the EMV issuer's private key and the card-reader terminal 102 uses a digital signature scheme based on public key encryption techniques to confirm the legitimacy of the ICC-resident static data 202 . This arrangement allows detection of unauthorized alteration of data after personalization. For more information regarding static data 202 authentication in ICC-EMV, the reader is referred to the EMV specification, EMV 2000 Book 2, from EMVco.
[0031] Similarly, for mobile-EMV, the EMV-ticket 200 may also contain the EMV signed static data 202 mentioned above. The signed static data 202 may also contain the EMV issuer's public key (contained in the certificate) corresponding to the EMV issuer's private key that was used to generate the signature on the static data 202 . The EMV card-reader terminal 102 may use this certificate to verify the signature of the static data 202 . As in the case of ICC-EMV, the EMV card-reader terminal 102 may contain the Public Key Certificate Authority (CA) root certificate to which the EMV issuer's public key is connected.
[0032] In some embodiments, the type of data included in the signed static data 202 includes application data. An example of such application data may be the Application Interchange Profile (AIP), which specifies the application functions supported by the ICC. Thus, some of the information contained in the AIP determines whether: offline static data 202 authentication is supported, offline dynamic data 204 authentication is supported, cardholder verification is supported, terminal risk management needs to be performed, and EMV issuer authentication is supported. A more complete list of API is available at EMV 2000 Book 3, Annex C.1, Page 90, from EMVco.
[0033] For unsigned dynamic data 204 , such as program counters and the like, it is useful to understand that, presently, EMV transactions can be completed offline or online. Offline means that the EMV card-reader terminal 102 does not need to connect to an EMV issuer to receive transaction authorization, whereas online means that the EMV card-reader terminal 102 must connect to an EMV issuer for transaction authorization. When an EMV transaction is completed online, the EMV issuer may provide command scripts to the EMV card-reader terminal 102 be delivered to the integrated chip card 110 . The command scripts perform functions that are not necessarily relevant to the current transaction, but are important for the continued functioning of the application in the integrated chip card 110 . Command script processing is provided to allow for functions that are outside the scope of the EMV specification and may be done differently by various issuers or payment systems. Examples of such functions may include unblocking of offline PIN, update of transaction counters, and so on.
[0034] In accordance with embodiments of the invention, mobile-EMV also provides for dynamic updates of data. The dynamic data 204 part of the EMV-ticket 200 may contain, for example, data that needs to be updated by the EMV issuer after the completion of an EMV transaction. Thus, when the transaction is completed online, the EMV issuer may send a command script for updating the data to the EMV-proxy. Since the EMV-proxy possesses the user's EMV-ticket 200 , it may update the dynamic data 204 in the EMV-ticket 200 . The dynamic data 204 in the EMV-ticket 200 , however, is not signed, as in the case of an ICC-EMV transaction.
[0035] With unsigned EMV data 206 , presently, ICC-EMV requires certain information, both mandatory and optional, to be stored in the integrated chip card 110 . Tables 1 through 3 below show examples of the type of data that needs to be present in the integrated chip card 110 according to the EMV specification. With mobile-EMV, however, this data (i.e., the data contained in Tables 1 through 3) may be stored instead in the EMV-ticket 200 in the personal trusted device 118 .
TABLE 1 Tag Value Presence ‘5F24’ Application Expiration Date M ‘5A’ Application Primary Account Number (PAN) M ‘8C’ Card Risk Management Data Object List 1 M ‘8D’ Card Risk Management Data Object List 2 M
[0036] Table 1 lists the data objects that must be present in the integrated chip card 110 in certain files that are read using the READ RECORD command. All other data objects defined in the EMV specification to be resident in these files are optional. In order to store these same data objects in the EMV-ticket 200 of the personal trusted device 118 , protective measures must be taken to prevent them from being altered or misused. Therefore, in some embodiments of the invention, none of the data objects in Table 1 are exposed for user viewing. In another approach, the data objects in Table 1 (or the sensitive portions thereof) may be encrypted so that the user is only able to see a label identifying the EMV-ticket 200 . In a preferred embodiment, sensitive data, whether encrypted or not, is not displayed to the user.
[0037] Table 2 below lists the data objects required for offline static data 202 authentication (see, e.g., EMV 2000 Book 3, page 30). This data normally needs to be present to support offline dynamic data 204 authentication (see, e.g., EMV 2000 Book 3, page 31). However, in some embodiments of the invention, the personal trusted device 118 may omit the function of offline dynamic data 204 authentication. Therefore, in these embodiments, the data objects in Table 2 are not stored in the personal trusted device 118 .
TABLE 2 Tag Value ‘8F’ Certification Authority Public Key Index ‘90’ EMV issuer Public Key Certificate ‘93’ Signed Static Application Data ‘92’ EMV issuer Public Key Remainder ‘9F32’ EMV issuer Public Key Exponent
[0038] Table 3 below lists the data objects that are retrievable by the EMV card-reader terminal 102 using the GET DATA command and not the READ RECORD command.
TABLE 3 Tag Value Presence ‘9F36’ Application Transaction Counter (ATC) M ‘9F17’ PIN try counter O ‘9F13’ Last online ATC Register O
[0039] In general, the presence of critical information in the EMV-ticket 200 requires secure handling, storage and copy protection during transmission from the EMV issuer 104 to the personal trusted device 118 , from the personal trusted device 118 to the EMV-proxy 114 and from the EMV-proxy 114 back to the personal trusted device 118 . Therefore, in accordance with embodiments of the invention, the personal trusted device 118 may carry (a) an EMV-specific service certificate from the EMV issuer, and (b) the EMV data 206 object as described with respect to the EMV-ticket 200 above. However, the personal trusted device 118 is not required to carry the full EMV application as required by the EMV specification, since the functions performed by the application have been delegated to the EMV-proxy.
[0040] As for provisioning of the EMV-ticket 200 , various mechanisms may be used to transfer the EMV-ticket 200 from the EMV issuer 104 to the personal trusted device 118 . These mechanisms may include: download by inserting the personal trusted device 118 in docking station at the EMV issuer's physical facilities; download via local wireless channels (e.g., Bluetooth, infrared) in the EMV issuer's physical facilities; given to the user in the form of a smart-card (contactless or otherwise); and over-the-air (OTA) download using the MeT ticketing download framework (see, e.g., the MeT Ticketing Specification from MeT Limited): After successful download, the EMV-ticket 200 may be stored in the ticket database as described in the MeT Ticketing Specification, and the MeT-ticket database may be stored inside a secure wallet in the personal trusted device 118 .
[0041] Finally, with regard to generation and provisioning of the EMV symmetric key, in an ICC-EMV transaction, a symmetric key is stored in the integrated chip card 110 . The symmetric key is then used to generate EMV application cryptograms that include a Message Authentication Code (MAC). The MAC is basically a one-way hash function with the addition of a secret key. The hash value is a function of both the data and the key and only someone with the key can verify the hash value. In mobile-EMV, the EMV symmetric key may be generated by the EMV issuer and delivered to the personal trusted device 118 for storage and subsequent generation of the EMV application cryptograms. In some embodiments, the EMV issuer delivers the EMV symmetric key to the personal trusted device 118 embedded inside an EMV-ticket 200 .
[0042] In other embodiments, the symmetric key may be encrypted and delivered to the personal trusted device 118 during an over-the-air (OTA) delivery. During OTA delivery, the EMV symmetric key embedded in the EMV-ticket 200 may be encrypted using the user's public key. Then, only the user's private key can decrypt the EMV symmetric key. Several ways exist by which the EMV issuer may obtain the user's public key.
[0043] Local transfer of EMV-ticket 200 containing the EMV symmetric key may also be possible, in which case, depending on the bearer transferring the key, encryption may not be required.
[0044] FIG. 3 illustrates a basic flow 300 for a typical ICC-EMV transaction, as specified by the EMV Specification. The mobile-EMV transaction follows similar steps and, therefore, the flow 300 is provided here as an example of these steps. The flow 300 assumes that the integrated chip card/personal trusted device has already connected to the EMV card-reader terminal, for example, by a physical interface. As can be seen, the transaction begins at step 302 , where the integrated chip card/personal trusted device initiates an application, such as a payment application. At step 304 , the integrated chip card/personal trusted device reads the data for the application from the data stored in the EMV-Ticket. At step 306 , the integrated chip card/personal trusted device authenticates the data for the application. Any restrictions on the transaction are processed at step 308 . At step 310 , the cardholder/user is verified. In parallel with steps 306 - 310 , the integrated chip card/personal trusted device also performs a terminal risk management at step 312 . Terminal risk management protects the acquirer, issuer and the whole system from fraud. It provides positive issuer authorization for high-value transactions and ensures that EMV transactions go online periodically to protect against threats that may be undetectable in an offline environmnent.
[0045] Next, the integrated chip card/personal trusted device performs a terminal action analysis at step 314 . During terminal action analysis, the cardholder system in ICC-EMV requires an online authorization of the transaction. The card determines whether to decline the transaction offline or to request an online authorization. At step 316 , the integrated chip card/personal trusted device performs a card action analysis. Card action analysis is outside the scope of the EMV specification and will therefore not be described here. A determination is made at step 318 whether the transaction is online or offline. If the transaction is an offline transaction, then the integrated chip card/personal trusted device concludes the transaction at step 320 . On the other hand, if the transaction is an online transaction, then at step 322 , the integrated chip card/personal trusted device sends the data for the transaction to the EMV issuer back office (via the EMV card-reader terminal). At step 324 , command scripts from the EMV issuer back office are processed by the integrated chip card/personal trusted device. Thereafter, the transaction is concluded at step 320 .
[0046] FIGS. 4A-4C illustrate a timing diagram 400 for an exemplary mobile-EMV transaction according to embodiments of the invention. Where the timing diagram 400 employs steps that are the same as or similar to the existing steps in an ICC-EMV transaction, an “(ICC-EM V)” designator will be used to indicate the similarity. Also, throughout FIGS. 4A-4C , dashed lines are used to indicate optional steps or actions, whereas solid lines are used to indicate mandatory steps or actions.
[0047] As can be seen, the mobile-EMV transaction begins at step 402 , where the user, through his personal trusted device, indicates to the EMV-proxy module in the EMV card-reader terminal that he wishes to make a MeT-EMV payment. At step 404 , the EMV-proxy module and the personal trusted device establish a secure wireless connection (e.g., a TLS/SSL connection) therebetween. At step 406 , the EMV-proxy module passes the payment contract to the personal trusted device. At step 408 , the personal trusted device presents (e.g., displays) the payment contract to the user. At step 410 , the user reads the payment contract and, at step 412 , he enters his personal identification number (PIN) to indicate his acceptance of the payment contract. By entering his PIN, the user unlocks his EMV signature private key. If the PIN is valid, the symmetric key stored in the personal trusted device is unlocked and used to generate cryptograms during the EMV transaction.
[0048] At step 414 , the personal trusted device checks the PIN and, if the PIN is valid, generates a digital signature and unlocks the symmetric key. At step 416 , the personal trusted device sends the signed payment contract to the EMV-proxy module. At step 418 , the EMV-proxy module checks the signature of the signed payment contract. If the EMV-proxy module determines that the signature on the signed payment contract is valid, then at step 420 , the EMV-proxy module requests an EMV-ticket, which has a special MIME type, from the personal trust device. At step 422 , the personal trusted device retrieves the EMV-ticket and sends the EMV-ticket at step 424 to the EMV-proxy module. At step 426 , the EMV-proxy module stores the EMV-ticket at the proxy and, at step 428 , initiates an EMV transaction with the EMV card-reader terminal module.
[0049] At step 430 , the EMV card-reader terminal module initiates a corresponding EMV application and, at step 432 , it sends an acknowledgment to the EMV-proxy module. At step 434 , the EMV-proxy module receives the acknowledgment and sends an appropriate response at step 436 . At step 438 , the EMV card-reader terminal module processes the response from the EMV-proxy module and, at step 440 , the EMV card-reader terminal sends a request for application data to the EMV-proxy module. At step 442 , the EMV-proxy module reads the application data stored in the EMV-ticket and sends an appropriate response at step 444 to the EMV card-reader terminal module. At step 446 , the EMV card-reader terminal module requests authentication of the application data from the EMV-proxy module. At step 448 , the EMV-proxy module reads the application data from the static data portion of the EMV-ticket and, at step 450 , sends the application data to the EMV card-reader terminal module. At step 452 , the EMV card-reader terminal module processes any restrictions on the user based on the application data. At step 454 , the EMV card-reader terminal module verifies the signature of the static data and, at step 456 , sends an appropriate confirmation of the verification.
[0050] At step 458 , the EMV-proxy module presents the cardholder verification results to the EMV card-reader terminal module. Thus far, only an offline verification has been performed. At step 460 , the EMV card-reader terminal module performs a terminal risk management and, at step 462 , performs a terminal action analysis. A new Application Cryptogram (AC) is generated by the EMV card-reader terminal module at step 464 and sent to the EMV-proxy module. At step 466 , the EMV-proxy module performs a card action analysis and generates a new AC, which is forwarded to the personal trusted device at step 468 . At step 470 , the personal trusted device computes its own AC using the symmetric key and, at step 472 , sends this AC to the EMV-proxy module. At step 474 , the EMV-proxy module forwards the AC to the EMV card-reader terminal module, which in turn may forward the AC to the EMV issuer back office, depending on whether the transaction is an online transaction or an offline transaction. In the example shown here, the transaction is an online transaction based on the type of cryptograms generated. At step 476 , the EMV card-reader terminal module forwards the AC to the EMV issuer back office.
[0051] At step 478 , the EMV issuer back office processes the online transaction and issues an authorization for the transaction. At step 480 , the EMV issuer back office may generate a command script for the personal trusted device. At step 482 , the EMV issuer back office delivers the command script to the EMV-proxy module (via the EMV card-reader general model 100 ). The EMV-proxy module updates its copy of the EMV-ticket in accordance with the command script at step 484 , and sends the result of the command script processing to the EMV issuer back office at step 486 . Thereafter, the EMV-proxy module sends the updated EMV-ticket to the personal trusted device at step 488 and deletes its copy of the same at step 490 . The EMV issuer back office, upon receiving confirmation of command script processing, sends a completion message to the EMV-proxy module at step 494 (via the EMV card-reader terminal module). The EMV-proxy module, in turn, sends a completion message to the personal trusted device at step 496 , where it is presented to the user at step 498 .
[0052] Generation of the application cryptograms was mentioned previously and may be implemented as follows. As has been mentioned above, a symmetric key stored in the EMV chip card is used to generate the application cryptograms in an ICC-EMV transaction. The following Table 4, as specified by the EMV specification, provides the recommended minimum set of data elements for the application cryptogram generation. The algorithm used for the generation of the application cryptograms in ICC-EMV has been provided in EMV 2000 Book 2. In some embodiments, mobile-EMV may use the same algorithm for generation of the application cryptograms.
TABLE 4 Value Source Amount, Authorised Terminal Amount Other (Numeric) Terminal Terminal Country Code Terminal Terminal Verification Results Terminal Transaction Currency Code Terminal Transaction Date Terminal Transaction Type Terminal Unpredictable Number Terminal Application Interchange profile ICC Application Transaction Counter ICC
[0053] Accordingly, the EMV symmetric key may either be (a) transferred to the EMV-proxy from the personal trusted device to have the EMV-proxy generate the cryptograms on behalf of the user, or (b) stored in the personal trusted device where the cryptograms will be generated. Option (a) requires a sufficient amount of trust to be placed on the EMV-proxy as well as on the mechanism to securely transfer the EMV symmetric key from the personal trusted device to the EMV-proxy, making it a higher risk approach if such trust is lacking. For this reason, option (b) (i.e. the EMV symmetric key stays in the personal trusted device) is preferred in some embodiments of the invention.
[0054] The symmetric key, in ICC-EMV, is provisioned by the EMV issuer back office into the integrated chip card card at the time of manufacturing of the card. In the mobile-EMV architecture, from a security point of view, the most logical place to store the EMV symmetric key would be the SE. However, the current Wireless Identity Module (WIM), developed by WAP for and maintained by the open Mobile Alliance specification, does not support symmetric key operations. Moreover, there may be business and technical issues related to post-issuance provisioning of the EMV symmetric keys into the SWIM card, which is a combination of a SIM card plus a WIM card. Nevertheless, in accordance with embodiments of the invention, the symmetric key storage place may be any of the mentioned places (e.g., smart-card, mobile equipment, etc.), as explained below.
[0055] In some embodiments, the concept of a security lock-box can be used for storage of EMV symmetric key and generation of EMV application cryptograms. Such a security lock-box is referred to here as a Sym-Locker (Symmetric Key Locker). A Sym-Locker may either be implemented in a smart-card based security element (i.e., the SWIM card), a smart-card without a security element, such as a standard SIM card (the SIM card provides symmetric key functionality), or in the card-reader terminal hardware. Regardless of how it is implemented, following are some of the requirements of the Sym-Locker.
[0056] Sym-Locker should provide APIs for secure provisioning of the EMV symmetric key into the locker. The API needs to allow provisioning of the symmetric key post issuance of the smart-card or the personal trusted device, depending on where the Sym-Locker is implemented. Also, the symmetric key needs to be securely stored in such a way that is sufficiently difficult to retrieve, tamper with, or copy the key. Further, the EMV symmetric key should never leave the Sym-Locker. EMV application cryptograms should be generated inside the Sym-Locker. The Sym-Locker should provide APIs to enable generation of the EMV cryptograms.
[0057] Users should not be asked to authenticate to the Sym-Locker in addition to the authentication to the EMV-proxy module because it would be unnecessary and may result in a degraded user experience. The Sym-Locker should be able to use the result of the user's authentication to the EMV-proxy module in order to generate and release the cryptogram for the mobile-EMV transaction. The Sym-Locker should be able to hold multiple EMV symmetric keys, each key corresponding to a separate integrated chip card issued by one or more financial institutions. Users may not browse the contents of the Sym-Locker keys. The EMV-tickets will provide an indication that the user was received at one or more financial institutions. Finally, the Sym-Locker should provide provisions to delete EMV Symmetric keys stored in the locker.
[0058] While the present invention has been described with reference to one or more particular embodiments, those skilled in the art will recognize that many changes may be made thereto without departing from the spirit and scope of the present invention. Each of these embodiments and obvious variations thereof is contemplated as falling within the spirit and scope of the claimed invention, which is set forth in the following claims. | A mobile terminal is enabled to conduct an EMV transaction. A wireless access node in the EMV card-reader terminal is provided for connecting a mobile terminal to the card-reader terminal. An EMV-proxy module executing in the card-reader terminal facilitates communication between the mobile terminal and the card-reader terminal. The EMV-proxy module lets the mobile terminal function in essentially the same way as a regular EMV chip card with respect to the card-reader terminal. The card-reader terminal may then conduct EMV transactions on behalf of the mobile terminal without requiring new software and/or hardware at the EMV issuer. EMV data is stored in the mobile terminal in the form of secure dynamic data objects. This Abstract is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. 37 CFR 1.72(b). | 6 |
FIELD OF THE INVENTION
[0001] The invention relates to an expander for radially expanding a tubular element by axial movement of the expander through the tubular element, and to a method of radially expanding a tubular element.
BACKGROUND TO THE INVENTION
[0002] Radial expansion of tubular elements has been applied, for example, in wellbores whereby a tubular casing is lowered into the wellbore in unexpanded state through one or more previously installed casings. After the casing is set at the required depth, an expander is moved through the casing to radially expand the casing to an inner diameter which is about equal to the inner diameter of the previously installed casing. In this manner it is achieved that the inner diameters of subsequent casings are about equal as opposed to conventional casing schemes which have stepwise decreasing casing diameters in downward direction. For example, WO-A-93/25800 teaches expansion of a casing in a wellbore by a solid expansion mandrel, the mandrel being pulled through the tubular or hydraulically pushed through the casing.
[0003] Expansion of tubulars is discussed in, for example, U.S. Pat. No. 6,557,640, and published U.S. patent application Ser. No. 10/382,325, the disclosures of which are incorporated herein by reference.
[0004] Expandable expansion cones are suggested, for example, in U.S. Pat. No. 6,460,615 the disclosure of which is incorporated herein by reference. Expansion of a cone within a casing requires that the casing be expanded as the expansion cone is expanded. This requires considerably more force than the force needed to pull a mandrel through the casing once the cone has been expanded. Further, if the lower casing is to overlap the previously installed casing and the inside diameter of the final casing is to remain constant through the overlap section, then the overlap section of the upper casing needs to be expanded by more than the remainder of the casing. Some provision for this greater expansion also needs to be provided.
SUMMARY OF THE INVENTION
[0005] In an aspect of the present invention, an expandable mandrel for plastic deformation of a tubular from an initial inside radius to an expanded inside radius around a centreline of the tubular is provided, the expandable mandrel comprising: a collar having an outside radius smaller than the initial inside radius; and a plurality of deformable segments extending from the collar wherein each of the deformable segments are deformable to the expanded inside radius and when deformed to the expanded radius together form an expansion surface having gaps between the deformed segments that are not aligned with the centerline of the tubular.
BRIEF DESCRIPTION OF THE FIGURES
[0006] FIG. 1 is a partial cross sectional view of a lower end of an expandable casing and cement shoe.
[0007] FIGS. 2A and 2B are partial cross sectional views of an expandable casing and an unexpanded duplex expansion cone within the expandable casing.
[0008] FIG. 3 is a partial cross sectional view of an expandable casing and a sealing assembly within the expandable casing.
[0009] FIG. 4 is a partial cross sectional view of a top end of an expandable casing and an upper sealing assembly.
[0010] FIGS. 5A and 5B are partial cross sectional views of an expandable casing and an unexpanded duplex expansion cone within the expandable casing.
[0011] FIGS. 6A and 6B are partial cross sectional views of an expandable casing and an expanded duplex expansion cone which has been prepared for expansion within the expandable casing.
[0012] FIG. 7 is a partial cross sectional view of a top end of an expandable casing and an upper sealing assembly set in a position for downward expansion by the duplex cone.
[0013] FIGS. 8A and 8B are partial cross sectional views of an expandable casing and an expanded duplex expansion cone within the expandable casing, after the duplex cone has been hydraulically forced to the cement shoe of the expandable casing.
[0014] FIGS. 9A and 9B are partial cross sectional views of an expandable casing and an expanded duplex expansion cone within the expandable casing, after the duplex cone has been prepared for upward expansion of the remainder of the expandable casing.
[0015] FIG. 10 is a partial cross sectional view of a top end of an expandable casing and an upper sealing assembly set in a position for upward expansion by the duplex cone.
[0016] FIG. 11 is an isometric view of an upward expansion cone.
[0017] FIG. 12 is an isometric view of a downward expansion cone.
[0018] FIG. 13 is an isometric view of a mandrel for expanding a duplex cone.
[0019] FIG. 14 is an isometric view of an upper seal bushing.
[0020] FIG. 15 is an isometric view of a retrieving tool within which an upper seal bushing may be retrieved.
DETAILED DESCRIPTION
[0021] In this specification, a tubular to be expanded is referred to as a casing, but it is to be understood that the term casing is meant to include any tubular to be expanded. A open hole liner or other wellbore tubular may be expanded by the methods and apparatuses described and claimed herein. The expansion apparatus of the present invention is referred to as a duplex expansion apparatus or mandrel because the apparatus can be used for expansion of a larger bell at the bottom of a casing, plus the remainder of the casing to a somewhat smaller diameter. The difference between the inside diameter of the bell compared to the remainder of the casing can be between about 0.2 and about 1.5 inches, or it could be about 0.5 inches. The difference in diameter can be about twice the expanded thickness of a casing to be expanded in the next lower section of the wellbore. The duplex expansion apparatus could be arranged to first expand the upper portion of the casing, and then converted to a larger diameter mandrel and used to expand the bell. Alternatively, and as shown in the apparatus discussed below, the apparatus could be configured to expand the bell first, and then contracted to a smaller diameter mandrel, but still a larger diameter than the unexpanded casing, and then used to expand the rest of the casing.
[0022] Referring now to FIG. 1 , a lower end of an expandable casing 101 with a cement shoe 102 is shown. A threaded joint 103 is provided to connect an aluminium cement shoe with the expandable casing 101 . The joint is a pin-down joint to permit downward expansion without the threads spreading due to the expansion of the upper section before the lower section. The entire shoe is aluminium or another millable or drillable material so that it can be readily removed for drilling of a subsequent open hole interval. The subsequent open hole interval may then be cased or left uncased. The cement shoe includes a bottom which preferably has teeth 104 to enhance opening of a hole if it has partially closed in the time interval between drilling and insertion of the expandable casing and secure the casing against rotation. Ports 105 are provided to ensure that cement can exit the cement shoe to an annulus between the casing 101 and formation 106 through which the wellbore 107 is drilled. The cement shoe includes a check valve 108 to keep cement from backing up into the casing once the cement has been placed in the wellbore by pumping through the casing. In this embodiment, the check valve includes a spring 109 that urges a valve seat 110 upward to close against a fixed valve seat 111 . Millable check valves and complete millable cement shoes are commercially available from many sources.
[0023] The cement shoe of the embodiment shown includes a sliding valve 112 for sealing the cement shoe for upward expansion of the expandable casing. The sliding valve 112 is shown in an open position in FIG. 1 . The sliding valve is held in an open position by a snap ring 113 . The sliding valve has a top 114 sealed to a cylindrical section 115 . The bottom of the sliding valve preferably has engaging teeth 116 for engaging with seat teeth 117 for holding the sliding valve in a fixed position when the valve is transferred to a closed position. In the open position slots 118 allow fluids to bypass the sliding valve for circulation through the casing and into the wellbore. Seals 119 are shown for providing a good seal against the cylindrical section of the sliding valve after the sliding valve has been transferred to a closed position.
[0024] The bottom of the casing is shown in FIG. 1 in a configuration in which it is inserted into the wellbore. Cement is circulated through the casing into the wellbore in this configuration.
[0025] Referring now to FIGS. 2A and 2B , a duplex expansion mandrel is shown within an expandable casing in a configuration in which the duplex mandrel is inserted into a wellbore within a formation, 106 . This apparatus, including the expandable casing, may be inserted into the wellbore through a casing in an upper section of the wellbore, the casing having been previously expanded by an expansion apparatus of the same design as the apparatus being inserted. Thus the final cased wellbore could have the same diameter from top to bottom, or through a plurality of different cased intervals.
[0026] The expandable casing preferably has a preexpanded section 201 within which the duplex cone is placed. The preexpanded section has been expanded by about, for example a half-inch diameter increase. This relatively short section of preexpanded casing is still of a smaller outside diameter than the inside diameter of the expanded casing, by for example 0.1 to 1.2 inches to permit insertion through a previously expanded casing. It is not desirable to have an extended length of preexpanded casing because a small clearance between the external surface of the preexpanded casing and the internal surface of an expanded casing would make insertion of the casing through an expanded casing problematic. But a short section of a relatively small clearance does not create significant problems when inserted through a previously expanded casing. The casing can be placed into the wellbore suspended from a collapsed upper expansion cone 204 . The collapsed upper expansion cone 204 has an outer diameter larger than the inside diameter of the unexpanded casing above the preexpanded section 201 .
[0027] A threaded joint 202 is preferably provided in the preexpanded section and this joint is preferably the only joint in the bell section of the expanded casing. This threaded joint allows the casing to be joined around the duplex expansion cone. Alternatively, additional joints in the bell section of the expanded casing could also optionally be preexpanded. Having joints in the bell section of the expanded casing being preexpanded reduces the expansion force required for expansion of the joints to the larger diameter. Because more force is required to expand joints, and more force is required to expand casing to a larger diameter, preexpansion of joints in the bell section is desirable because it would otherwise require additional expansion force compared to the remainder of the casing.
[0028] The duplex cone includes a lower cone 203 , an upper cone 204 , and expansion die 205 , all assembled on an assembly mandrel 214 . The assembly mandrel pulls and pushes the two cones over the die to expand the duplex cone.
[0029] In the configuration shown in FIGS. 2A and 2B , fluids may pass through the center of the unexpanded duplex cone assembly. A flow tube 206 hold flapper valves 207 open within a flapper valve assembly 208 . The flapper valve assembly also provides a seal for lower cone ports 209 in this initial configuration of the duplex cone assembly.
[0030] Wipers 210 are shown attached to the lower cone assembly for keeping the casing clean prior to expansion by the duplex cone.
[0031] The lower cone is held by the assembly mandrel in an initial position by first dogs 211 . Second dogs 212 will later hold the cone in a second position with respect to the assembly mandrel. A spacer 213 is shown between the expansion die and the upper cone 204 . Seal assemblies 215 are attached to the upper cone to aid in upward expansion. The pulling assembly and the upper cone are in fixed relationship to each other, and in a movable relationship to the assembly mandrel. The pulling assembly may have a plurality of pulling chambers 218 , two are shown, containing a lower piston 219 and an upper piston 222 . The pulling chambers 218 are in fluid communication with a flow path 220 through the assembly mandrel 214 through high pressure ports 221 . The lower pistons movement with respect to the assembly mandrel 214 is shown to be limited by retainer tie 223 . Movement of the upper piston 222 with respect to the assembly mandrel 214 is shown to be limited by the shoulder of pin box 224 .
[0032] Vent ports 217 maintain fluid communication between low pressure sides of the pulling chambers 218 and an annulus around the pulling assembly and the expandable casing 101 . Thus when there is a pressure differential between the flow path 220 and the annulus around the pulling assembly 216 , this pressure will be translated into force pulling the bottom expansion cone and pushing the upper expansion cone over the expansion die to form an expanded duplex cone. The assembly mandrel is movable with respect to the pulling assembly, and the pulling assembly is shown in a fixed relationship to a drill string 225 . As the term is used in this description, the drill string is generally a typical string of pipes used for circulation of drilling muds while transmitting rotating forces to a drill bit, but in the practice of the present invention, additional features may be included in segments of the drill string, and segments could be utilized that differ from the segments typically used while drilling the wellbore. The flow path from the drill string through the assembly mandrel is passed through a flow path seal 226 which maintains a sealed and sliding relationship between the pulling assembly and the assembly mandrel. Seals such as o-rings 227 could be provided to improve the sealing relationship. To enable assembly, the pulling assembly could be constructed of a middle section, 228 , a lower head, 229 , and an upper head 230 , with the three sections connected by two threaded connections, both of the threaded connections preferably in lower pressure segments of the pulling chambers.
[0033] In the configuration shown in FIGS. 2A and 2B , is the configuration in which the expandable cone is lowered into the wellbore, preferably through previously expanded casing. In this configuration there is no significant pressure differential between the flow path 220 and the annulus between the pulling assembly and the expandable casing 101 . The number of pulling chambers and pistons may be chosen to have ample force to expand the duplex cone even while expanding the casing around the duplex cone.
[0034] Referring now to FIG. 3 , a sealing assembly section is shown. The sealing section is in the drill string above the pulling assembly 216 , and within the expandable casing 101 . The sealing section includes seals 301 for maintaining force for downward expansion by the duplex cone. The seals may be, for example, Giberson cup packers available from Halliburton, of Ducan Okla. Two of the seals are shown but either one or a plurality may be provided as needed for effective sealing during the downward expansion.
[0035] Referring now to FIG. 4 , an upper end 401 of an expandable casing 101 is shown. The upper end of the expandable casing is fitted with bushing 402 for sealing for downward expansion. The bushing is removable and therefore preferably placed at the top of the expandable casing so that it will not have to slide out a great length of the expandable casing upon removal of the bushing. The bushing is preferably equipped with inside seals 403 and casing seals 404 . FIG. 4 shows a configuration in which the casing is inserted into the wellbore, with communication between the annulus between the drill string 225 and the expandable casing 101 and the wellbore above the expandable casing 101 . The bushing is notched (not shown) in the bottom so that a corresponding fin 405 in the first drill string box can catch the bushing, and remove it by twisting it out of the upper casing. Two opposing fins are shown in FIG. 4 . Removal of the bushing allows for clearance for joint tools and the duplex expansion assembly above the expansion cone. The purpose of the bushing is to provide a seal for downward expansion. The seal is provide between the inside surface of the bushing and the outside surface of a slidable section of drill string 406 . While the expandable casing and duplex cone assembly is suspended from the drill string, the weight of the casing and duplex cone assembly rests on slidable section shoulder 407 , and rotational forces can be transferred through splined section 408 . Flowpath seal 409 is provided so that leakage from the drill string flow path and the wellbore outside of the drill string is prevented.
[0036] Referring now to FIGS. 5A and 5B , with previously mentioned elements numbered as in previous figures, the duplex cone is shown in an unexpanded position configured to be expanded upon pressurization of the flowpath within the assembly mandrel. This configuration is accomplished by inserting dart 501 , which is stopped in flow tube 206 . Although a dart is shown to be of an elongated shape, a ball or another shape could be utilized. The flow tube could be held in the initial position by a shear pin or a snap ring 231 that yields upon downward force being applied to the flow tube. The dart 501 includes a seal section 502 that seals inside of the flow tube, and the flapper valve 207 seals against the flapper valve seat 503 above the flow tube. After the flow tube 206 moves to the lower position, flapper valves 207 close. An advantage of the embodiment shown is that the flapper valve, including the seats for the valve, are protected by the flow tube from circulating fluids and cements prior to insertion of the dart 501 . Thus, they are clean and more likely to seal. The flapper valves 207 are therefore primary seals, but seals between the flapper assembly and the flow tube, and the flow tube and the dart provide secondary seals for sealing the inside of the flow path to permit expansion of the duplex cone.
[0037] Referring now to FIGS. 6A and 6B , the duplex cone within an expandable casing is shown with the duplex cone forced into an expanded position. This expanded position is achieved by over pressuring the fluids in the drill string with respect to the fluids outside of the drill string and forcing the pistons 219 and 222 into upper positions within the pulling chambers 218 .
[0038] Referring now to FIG. 7 , the top end of the expandable casing is shown configured for downward expansion of the casing. After expansion of the duplex cone, the cone is supported by the casing at the point it is expanded, and the casing can be set on the bottom of the wellbore. The drill string can therefore be lowered to engage the slidable section of the drill string 406 into the bushing 402 . This is the position shown in FIG. 7 . The slidable section shoulder 407 , when separated from the flow path seal 409 , has ports for communication of fluid from within the drill string to the annulus around the drill string. The seal at the top of the expandable casing permits pressurization of the volume between the drill string with the expandable casing. Seals 301 , shown in FIG. 3 hold the pressure between drill string 225 and the expandable casing 101 at the lower end. Downward pressure for downward expansion is thereby applied across the whole internal cross section area of the unexpanded expandable casing, due to pressure differential across flapper valve and drill string in addition to pressure differential across seals 301 . This downward pressure forces the duplex cone to the position shown in FIGS. 8A and 8B .
[0039] Referring now to FIGS. 8A and 8B , the nose of the lower cone 108 has forced the sliding valve 112 into a closed position, providing a positive seal at the bottom of the expandable casing. Seals such as o-rings 119 help maintain a positive seal. Snap ring 113 , shown in FIG. 1 , is sheared by the force of the downward movement of the duplex cone assembly thereby allowing the sliding valve to move downward. Dimensions of the nose of the lower cone and the cement shoe are selected so that in the resting position at the bottom of the well, the lower expansion cone has expanded the expandable casing 101 to the bottom of the expandable casing through threaded joint 103 so that only millable or drillable material remains below the expanded portion of the casing.
[0040] Referring to FIGS. 9A and 9B , the duplex cone configured for upward expansion is shown. To configure the duplex cone for upward expansion, the lower cone 203 is slid down the expansion die 205 so that it outer diameter is equal to or less than the outer diameter of the upper cone when the upper cone is engaged with the expansion die. The lower cone 203 was therefore able to expand the lower portion of the expandable casing to a diameter that is, for example, about a half of an inch greater than the diameter to which the rest of the expandable casing will be expanded. This forms a bell at the bottom of the casing into which a next lower casing section may be expanded after the next lower segment of the well is drilled.
[0041] The embodiment shown provides for movement of the lower cone to an unexpanded position by movement of the flapper valve assembly to a second position. The diameter of the duplex expansion apparatus is thereby changed from a larger diameter to a slightly lesser diameter to provide for expansion of the remainder of the casing to a less expanded state than the bell portion of the casing. Movement of the lower cone is provided by over pressuring the fluids within the flow path to a selected pressure greater than that used for the downward expansion. This pressure is selected to be high enough to shear a shear pin or snap ring holding the flapper valve assembly in the earlier position. For example, if the downward expansion is performed at a pressure of 5000 psia, an over pressure to 5500 psia may be selected to move the flapper valve assembly to the final position. The movement of the flapper valve assembly does two things. First, it uncovers lower cone ports 209 , allowing fluid communication between the inside of the drill string and the volume inside the expandable casing and outside of the duplex cone assembly. The second thing movement of the flapper assembly does is to remove inward support for the first dogs 211 . The first dogs are supported on fingers extending from a cylinder section of the assembly mandrel. The fingers are flexible enough to bend inward when the support of the flapper assembly is removed. The inward movement of the first dogs can be improved by providing that the surfaces between the dogs and the lower cone rest are at a slight angle from normal to the centreline of the duplex cone apparatus. Further, the fluid pressure within the flow path will exert a force on the lower cone tending to urge the lower cone away from the assembly mandrel. When the first dogs are disengaged, the second dogs 212 will catch support surfaces 901 to permit recovery from the wellbore of the lower cone with the rest of the duplex cone assembly.
[0042] Referring now to FIG. 10 , the top end of the expandable casing is shown configured for upward expansion of the expandable casing 101 . For upward expansion of the expandable casing, the slidable section 406 is pulled back upward to engage the slidable section shoulder 407 with the flow path seal 409 . Thus the drill string and the flow path are connected and isolated from the wellbore outside of the drill string above the upward expansion sealing assemblies 215 . As the drill string is raised along with upward movement of the duplex expansion cone, the first tool joint to contact the bushing 402 will remove the bushing so it will not block removal of the remainder of the duplex cone apparatus. The first tool joint may include a fin, or a plurality of fins 405 (two opposing fins shown) which will catch on slots in bushing 402 to allow engagement with the bushing, and rotation of the bushing to a position from which it may be removed from the top of the expandable casing.
[0043] Referring now to FIG. 11 , the upper expansion cone 204 is shown. The expandable cone section is divided into a plurality of deformable segments 1101 extending from base 1102 . The base has a smaller diameter than the initial inside diameter of the casing. Each of the deformable segments includes a deformable portion 1103 and an expansion surface 1104 which contacts the casing during an expansion process. In the embodiment shown, the segments are angular to the centreline of the cone over the expansion surface 1105 . The expansion surface is the surface that contacts the inner surface of the expandable casing during expansion. In the deformable portions of the deformable segments, the segments may be aligned with the centreline of the expandable mandrel. With the expansion surfaces aligned at an angle to the centreline of the expandable mandrel, the resulting expanded casing is expanded to a round shape. If the segments were aligned with the centerline of the cone, pipe expanded by the cone would have small ridges like rifling on the inside of the expanded pipe. This would be caused by gaps that would be formed when the deformable segments are deformed to the expanded diameter of the expandable mandrel. When the gaps resulting from the expansion of the cone over the expansion die are at an angle relative to the centerline of the apparatus (for example, between five and fifteen degrees from parallel to the centerline of the apparatus) the cone will expand the casing more evenly than it would with deformable segments. This more even expansion, or expansion to a more perfect circular cross section, is desirable. The deformable segments are, for example, deformed when the cone is pressed over the expansion die, so that the cone will partially retake its original form when force holding the cone onto the die is removed, or at least be readily bent back to the smaller diameter with a small amount of pressure so that the lower cone may be passed through the upper portion of the expanded casing which has not been expanded to as large of an internal diameter as the expanded lower cone and other forces applied.
[0044] Referring now to FIG. 12 , the lower expansion cone 203 is shown. The lower expansion cone is similar to the upper expansion cone in operation. Lower cone segments 1201 extend from lower cone base 1202 to form segments that can expand outward when the lower cone is forced over an expansion die. Each of the deformable segments includes a deformable portion 1203 and an expansion surface 1204 which contacts the casing during an expansion process. Lower cone ports 209 provide communication for fluids from within the flow path to outside of the duplex cone for upward expansion.
[0045] Referring now to FIG. 13 , the assembly mandrel is shown. First dogs 211 and second dogs 212 are shown with the first dogs on fingers 1301 . Depression 1302 for holding retainer tie 219 , and vent ports 217 are shown for the piston section of the mandrel. Spacer 213 , separating the expansion die from the upper cone is shown. Retainer tie 223 may be attached to the assembly mandrel, or may be fabricated as a part of the assembly mandrel.
[0046] Referring now to FIG. 14 , the upper end of the expandable casing 101 is shown with a j-hook notch 1401 for securing the bushing. FIG. 15 shows the bushing 402 with a load pin 1501 suitable for engagement into the j-hook notch of FIG. 14 . Casing seals 403 provide for sealing between the bushing 402 and the expandable casing 101 .
[0047] Referring now to FIG. 15 , bushing 402 is shown with key slot 1502 providing for engagement with a fin 405 attached to the first tool joint below the bushing. The fin 405 will catch in the key slot 1502 , and continued rotation of the drill string will move the load pin 1501 to the vertical section of the j-hook notch in the expandable casing 101 . Continued upward force may lift the bushing from the upper end of the expandable casing. Load pin 1501 may be held in the horizontal portion of the j-hook notch 1401 by action of a shear pin. The shear pin may be failed by torque applied through the fin 405 . | An expandable mandrel is provided for plastic deformation of a tubular from an initial inside radius to an expanded inside radius around a centreline of the tubular is provided. The expandable mandrel includes: a collar having an outside radius smaller than the initial inside radius; and a plurality of deformable segments extending from the collar wherein each of the deformable segments are deformable to the expanded inside radius and when deformed to the expanded radius together form an expansion surface having gaps between the deformed segments that are not aligned with the centerline of the tubular. | 4 |
TECHNICAL FIELD
The present invention relates generally to a cutting system for trees, vegetation and a wide range of other objects; and, more particularly, to methods and apparatus which are particularly, but by no means exclusively, suited for cutting standing timber such, for example, as the harvesting of Christmas trees and the like. In its principal aspects, the invention incorporates provisions for storing potential energy in one or more accumulators by, for example, compression of gaseous or other fluid material, or by use of compression springs or the like; and, for thereafter utilizing such stored potential energy to drive one or more cutting elements through a cutting path and wherein the inertial forces generated by at least certain of the driven components are utilized to partially recompress the expandible material in the accumulator or other potential energy storage device preparatory to positioning the apparatus in readiness for its next cutting cycle.
BACKGROUND OF THE INVENTION
Prior to the advent of the present invention, there has been a long-felt and ever increasing demand for power driven portable cutting systems which can be used in a wide variety of agricultural and/or forest related applications such, for example, as in the harvesting of Christmas trees, forest thinning operations, removal of brush in forest maintenance and/or reforestation projects, etc.; as well as in similar cutting operations. Indeed, as the ensuing detailed description proceeds, those skilled in the art will appreciate that in its broader aspects the present invention also fills a further somewhat related need for reliable power equipment which is characterized by low energy consumption requirements and which can be employed on a cost-effective basis for mowing fields, lawns and similar vegetated areas.
Many different types of systems have been developed for use in such cutting applications; and, indeed, a wide variety of such systems have been, and are being, employed today including, but not limited to, a multiplicity of different types of power mower devices. Two such tree cutting systems are disclosed in, for example, U.S. Pat. Nos. 3,627,022--Fulghum, Jr. and 3,857,425--Wiklund. Thus, in the aforesaid Fulghum, Jr. patent, the patentee discloses a timber shearing apparatus wherein a shear blade is hydraulically driven towards an anvil for purposes of cutting a tree trunk positioned within the jaws of the apparatus. Wiklund, on the other hand, discloses a power operated frusto-spherical, cap-shaped saw blade which is also moved through a cutting path by means of an hydraulic cylinder. No provision is made in either of these patent disclosures for storing potential energy in an energy accumulation device and thereafter utilizing such stored potential energy to drive a cutting blade through a cutting path.
Other conventionally employed apparatus used for purposes of felling timber, harvesting Christmas trees, and the like include power-operated chain saws as well as axes and similar cutting devices, all of which are highly dangerous and require considerable expertise and dexterity on the part of the user in order to effectively employ such equipment for their intended purposes without inflicting injury to and/or otherwise fatiguing the user.
SUMMARY OF THE INVENTION
The present invention provides simple, relatively inexpensive, energy efficient, power operated cutting systems which can be readily used by relatively untrained individuals for purposes of cutting a wide variety of objects--e.g., particularly, but not exclusively, timber, Christmas trees and similar vegetation; and, which may also be used to cut steel or other metal, synthetic or natural objects--yet, wherein the perilous operation conventionally associated with such cutting equipment is essentially avoided. More specifically, the present invention employs a system wherein the cutting blade(s) is (are) driven by means of stored potential energy--for example, in the form of compressed gas, other suitable compressed fluid, or in a compressed spring or the like--which is permitted to expand so as to generate sufficient kinetic energy as to drive the cutting element(s) through its (their) cutting cycle; and, wherein inertial forces developed by at least certain of the driven components and, in some instances, excess kinetic energy developed which is not required for the cutting operation, is and/or are employed to at least partially recompress the expanded motive fluid or spring prior to a subsequent cutting cycle.
To this end, the various exemplary embodiments of the invention disclosed and hereinafter described contemplate a rotatable cutting blade which is driven through a substantial portion of its rotational cutting path by means of expanding gases (or expanding compressed spring means) which are contained within a piston/cylinder combination--e.g., an "accumulator"--for purposes of shifting the piston axially through a power expansion stroke and converting lineal piston movement to rotational movement of the blade supporting shaft through a suitable crankshaft. The arrangement is such that inertial forces generated during the power expansion drive stroke by at least certain of the rotationally driven components--such, for example, as the crankshaft--can be employed to initiate reverse axial piston movement during its compression stroke for permitting at least partial recompression of the expanded fluid medium or spring, with full recompression being obtained by means of a fluid actuated positioning mechanism and a suitable, but completely conventional, one-way positioning clutch coupled to the crankshaft, such as a one-way positioning clutch which is driven unidirectionally by a hydraulic motor. However, as the ensuing description proceeds, those skilled in the art will appreciate that in its broader aspects, the present invention readily permits of use of the energy conversion systems described herein in conjunction with lineal and/or reciprocating cutting systems (not shown) with equal facility.
As a consequence of the foregoing arrangement, the cutting blade may be driven rapidly through its effective cutting path--e.g., through a Christmas tree trunk, vegetation or similar natural, synthetic or metal objects--so as to shear the object(s) being cut without shattering and/or splitting the object(s), an undesirable result that is prevalent in most timber shearing operations, particularly when the cutting operation is being conducted at relatively low temperature conditions. The various systems disclosed and described herein have further proven to be not only highly effective but, additionally, highly energy efficient.
DESCRIPTION OF THE DRAWINGS
These and other objects and advantages of the present invention will become more readily apparent upon reading the following detailed description and upon reference to the attached drawings, in which:
FIG. 1 is a fragmentary perspective view, partially cut away to reveal interior components, of a highly simplified tree cutting apparatus embodying features of the invention and which is particularly, but by no means exclusively, suited for cutting Christmas trees, brushing and/or similar timber thinning operations;
FIG. 2 is a fragmentary, vertical elevational view, partially in section, here illustrating details of the operating components employed in the cutting device shown in FIG. 1;
FIGS. 3A through 3C are bottom views, partially in section, of the cutting apparatus shown in FIGS. 1 and 2, here illustrating the cutting blade, accumulator and crankshaft in three successive operating positions during a single cutting revolution--viz., FIG. 3A illustrating the apparatus during the compression cycle of the accumulator while the fluid medium is being compressed; FIG. 3B illustrating the apparatus with the accumulator piston and crankshaft in their top dead center positions in readiness for a fluid operated cutting stroke; and, FIG. 3C illustrating the apparatus as the completion of the power driven cutting stroke with the piston and crankshaft having passed their respective bottom dead center positions;
FIG. 4 is a fragmentary, vertical elevational view, partly in section, of a slightly modified cutting apparatus similar to that shown in FIGS. 1-3C and also embodying features of the present invention;
FIG. 5 is a fragmentary, vertical elevational view, partially in section, of yet another modified form of the invention similar to that depicted in FIG. 2, but here illustrating the apparatus with a pair of oppositely positioned accumulators acting in phase and serving to balance the forces imparted to the crankshaft;
FIG. 6 is a bottom view, partially in section, of the apparatus shown in FIG. 5, here depicting the accumulator pistons in their top dead center positions in readiness for initiation of a cutting cycle;
FIG. 7 is a fragmentary, vertical elevational view, partly in section, similar to FIGS. 2 and 5, but here illustrating yet another modified form of the invention employing two accumulators which are 180° out of phase for purposes of alternately driving the crankshaft through successive 180° angles;
FIG. 8 is a bottom view of the apparatus shown in FIG. 7;
FIG. 9 is a fragmentary, vertical elevational view, partially in section, of yet another slightly modified form of the invention, here employing a crankshaft and connecting linkage arrangement for driving the cutting blade through an oscillatory path as opposed to a rotational path;
FIGS. 10A through 10C are diagrammatic bottom views of the apparatus shown in FIG. 9, here respectively depicting the apparatus: (i) in an inactive static position preparatory to a cutting operation (FIG. 10A); (ii) at that point in an operational cutting cycle where the accumulator piston is at top dead center in readiness to initiate a cutting operation (FIG. 10B); and (iii), wherein the accumulator piston is at bottom dead center immediately following completion of the cutting operation and at the beginning of its compression stroke wherein the rotating blade is driven in the opposite direction preparatory to the next cutting operation;
FIG. 11 is a fragmentary, vertical elevational view, partly in section, similar to FIG. 2, but here illustrating the apparatus employing only a single one-way clutch in conjunction with a one-way ratcheting latch mechanism; and,
FIG. 12 is a bottom view of the apparatus shown in FIG. 11.
While the invention is susceptible of various modifications and alternative forms, specific embodiments thereof have been shown by way of example in the drawings and will herein be described in detail. It should be understood, however, that it is not intended to limit the invention to the particular forms disclosed; but, on the contrary, the intention is to cover all modifications, equivalents and alternatives falling within the spirit and scope of the invention as expressed in the appended claims.
DETAILED DESCRIPTION
Turning now to the drawings, and with particular attention being initially directed to FIG. 1, there has been illustrated in highly diagrammatic form a simple cutting apparatus, generally indicated at 20, embodying features of the present invention--such apparatus 20 having here been illustrated in the form of a portable cutting device mounted on a wheeled frame 21 and having a rotatable cutting blade 22 adapted to be unidirectionally driven through a 360° cutting angle for cutting, for example, a Christmas tree 24 or similar natural, synthetic or metal objects. To this end, the apparatus frame 21 is generally upright, terminating at its uppermost end in a rearwardly projecting handle assembly 25, and having a pair of ground-engaging wheels 26, 28 journaled for rotation at the lower extremity of the frame 21. Blade 22 is mounted on the lower end of a generally vertical crankshaft 29 having its uppermost end coupled through a conventional one-way clutch 30 to a fluid actuated piston/cylinder combination 31/32. Thus, as best illustrated in FIG. 2, the piston/cylinder combination 31/32 includes a double-acting reciprocating piston 31 mounted within a positioning cylinder 32 and a pair of inlet/outlet lines 34, 35 for coupling the cylinder chambers 36, 38, respectively, on opposite sides of piston 31 to a suitable source of pressurized fluid, shown in FIG. 1 in block form as a conventional source of motive power--e.g., an hydraulic pump 39. The power means employed for driving the hydraulic pump 39 are completely conventional and, therefore, are neither illustrated nor described in detail herein. Rather, it should suffice to state that the pump 39 may be powered by a conventional motor (not shown); while a suitable and completely conventional control valve 40 is preferably mounted on the handle assembly 25 in a position to permit convenient operation by the user so as to enable pressurization and depressurization of the cylinder chambers 36, 38 during a crankshaft positioning cycle on the one hand and during repositioning of the outer shell of the conventional one-way positioning clutch 30 following each cutting revolution of blade 22 and preparatory to initiation of the next succeeding cutting revolution. A second completely conventional one-way clutch 41, which may be identical to clutch 30, is preferably mounted in the apparatus frame at the output end of crankshaft 29 for preventing reverse rotation of the crankshaft during repositioning of the outer shell on the positioning clutch 30.
In order to provide a source of stored potential energy for driving the cutting blade 22 rotationally, the exemplary apparatus 20 includes a second piston/cylinder combination 42/44 (FIGS. 1 and 2) or "accumulator" pivotally mounted to the frame 21 and having its piston 42 coupled directly to crankshaft 29. In carrying out the invention as incorpoated in the exemplary embodiment shown in FIGS. 1 and 2, the accumulator 42/44 is preferably designed such that cylinder chamber 45 may be initially charged with a compressible fluid--e.g., a suitable pressurized gas--at any appropriate operating pressure such, merely by way of example, as 1,000 psi; while cylinder chamber 46 may be vented to atmosphere (not shown) or, if desired, may be maintained at a relatively low, or even negative, pressure.
To enhance the safety of the apparatus 20 and to shield the rotating components, exemplary apparatus is preferably provided with a housing 48 and a blade cover or guard 49 which are secured to, mounted on, and supported by the frame 21 in any suitable manner, as best shown in FIG. 1.
In operation, and as will best be understood by reference to FIGS. 1, 2 and 3A through 3C conjointly, the operator will first position the handle mounted control valve 40 so as to pressurize chamber 38 (FIG. 2) in the positioning piston/cylinder combination 31, 32, thus urging the piston 31 to the left as viewed in FIG. 2 and, through the one-way clutch 30, rotating crankshaft 29 in a clockwise direction as viewed in FIGS. 3A-3C from the position shown in FIG. 3A to that shown in FIG. 3B wherein the piston 42 of the accumulator 42/44 is in its top dead center position, fully compressing the gas charge contained within accumulator chamber 45 (FIGS. 2 and 3B). At this point in the operation, additional incremental movement of positioning piston 31 to the left as viewed in FIG. 2 serves to rotate the crankshaft 29 in a clockwise direction as viewed in FIG. 3B through a sufficient angle as to pivot accumulator cylinder 44 in a counterclockwise direction about its pivotal connection 50 to housing 48; and, as a consequence, accumulator piston 42 moves slightly past its top dead center position shown in FIG. 3B. Under these conditions, the compressed fluid medium in accumulator chamber 45 is permitted to rapidly expand, driving accumulator piston 42 downwardly and imparting sufficient rotational torque to the crankshaft 29 to rapidly drive the shaft and cutting blade 22 secured thereto in a clockwise direction through a rotational angle of approximately 180° from the position shown in FIG. 3B towards that shown in FIG. 3C, thus rapidly shearing the tree trunk 24. Due to the inertial forces generated as a result of such rapid rotation of the crankshaft 29 and blade 22, sufficient energy is provided to cause the blade 22 and shaft 29 to continue their clockwise rotation beyond the point shown in FIG. 3C, thus initiating upward axial movement of accumulator piston 42 and partially recompressing the expanded fluid medium in accumulator chamber 45.
As such time as the inertial forces are completely dissipated, the crankshaft 29 and blade 22 cease rotating in a clockwise direction; but, at this point in the operation cycle, the one-way positioning clutch 41 located at the output end of crankshaft 29 serves to prevent expansion of the partially compressed fluid medium in accumulator chamber 45 which would otherwise serve to drive the accumulator piston 42 downwardly tending to drive the crankshaft 29 and blade 22 in a counterclockwise direction.
Once the accumulator piston 42 has passed the top dead center position shown in FIG. 3B and commenced its power expansion cutting stroke, the operator manually shifts control valve 40 (FIG. 1) so as to depressurize chamber 38 and pressurize chamber 36 in positioning cylinder 32 (FIG. 2), thus driving positioning piston 31 to the right as viewed in the drawing and rotating the outer shell of the one-way positioning clutch 30 in the opposite direction in preparation for a further positioning cycle. Consequently, when the cutting blade 22 and crankshaft 29 complete their power driven cutting stroke, the positioning one-way clutch 30 may be again actuated by the operator in the manner previously described through manipulation of control valve 40 to again pressurize chamber 38 in positioning cylinder 32 so as to cause the positioning piston 31 to shift to the left as viewed in FIG. 2, thus driving the crankshaft 29 and cutting blade 22 in a clockwise direction towards and through the position shown in FIG. 3A, and towards the position shown in FIG. 3B where the accumulator piston 42 is again at its top dead center position in readiness for the next cutting operation. Moreover, if desired, the apparatus may include a suitable conventional limit switch 51 (FIG. 2) for sensing the rotational position of the crankshaft 29 and for controlling a suitable and completely conventional electrical or hydraulic circuit (not shown) for temporarily prohibiting further pressurization of chamber 38 in positioning cylinder 32, thus causing rotational movement of the rotatable cutter components--e.g., the crankshaft 29 and blade 22--to terminate at a point just prior to the time that the accumulator piston 42 reaches the top dead center position shown in FIG. 3B. As a consequence of this arrangement, the operator may move the cutting apparatus 20 (FIG. 1) to a new position proximate the next tree 24 or other object to be cut, at which point the cutting cycle may be again manually initiated through any desired override circuitry (not shown) which enables further pressurization of chamber 38 in positioning cylinder 32 and consequent additional clockwise rotational movement of crankshaft 29 so as to shift accumulator piston 42 past its top dead center position (FIG. 3B) and to again initiate a power cutting stroke. And, of course, those skilled in the art will appreciated that when the exemplary apparatus 20 shown in FIG. 1 is intended to function as a high speed, continuously rotating cutter--e.g., when it is to function as a power mower, debrusher, thinner, or the like--it is within the scope of the invention to provide a completely conventional closed loop hydraulic system wherein the positioning piston/cylinder combination 31/32 is automatically operated as a function of the position of the crankshaft 29, in which event the control valve 40 would be replaced by manually operable START/STOP switches (not shown).
As thus far disclosed, the exemplary form of the invention depicted in FIGS. 1-3C has been illustrated and described in connection with apparatus 30 employing a fluid actuated accumulator 42/44. However, those skilled in the art will appreciate that the accumulator 42/44 need not be fluid actuated; but, rather, can take other forms without departing from the spirit and scope of the invention, at least insofar as provision is made for storing potential energy used to drive the cutter blade 22 through its cutting stroke. Thus, referring to FIG. 4, it will be noted that a modified cutting apparatus, generally indicated at 52, has been shown which, in terms of overall structural configuration and operation, is essentially identical to the apparatus 20 shown and described above in connection with FIGS. 1-3C. Because of the virtual identity in structural components, like reference numerals have been used to designate identical components in the two exemplary embodiments. In this instance, however, rather than charging the accumulator chamber 45 with a pressurized gas or the like, a suitable compression-type coil spring 54 is positioned in the chamber 45 with one end bottomed on accumulator piston 42 and its opposite end bottomed at the end of the accumulator cylinder 44. The operation of the two systems--viz., the apparatus 20 of FIGS. 1-3C and the apparatus 52 shown in FIG. 4--is identical; but, in this instance, as the positioning piston/cylinder combination 31/32 is adjusted to shift the accumulator piston 42 to its top dead center position (i.e., to a position such as that shown in FIG. 3B), the compression-type coil spring 54 is compressed so as to store potential energy therein. Consequently, when the positioning piston/cylinder combination 31/32 serves to rotate the crankshaft 29 sufficiently far that the accumulator piston 42 passes its top dead center position, the compressed spring 54 is free to expand so as to convert the potential energy stored therein to kinetic energy, serving to drive the crankshaft 29 and cutter blade 22 through a power expansion cutting stroke.
Referring next to FIGS. 5 and 6, yet another exemplary embodiment of the invention has been illustrated and will be described below. In this instance, however, the exemplary cutting apparatus, generally designated at 55, is provided with a pair of identical accumulator piston combinations 42/44 and 42'/44' which are disposed on opposite sides of the crankshaft 29' and which are operated in phase. That is, in the exemplary embodiment shown in FIGS. 5 and 6, both accumulator pistons 42 and 42' are positioned at their top dead center positions so as to fully compress the gaseous or other fluid medium within the accumulator chambers 45, 45'. As a consequence, when the positioning piston/cylinder combination 31/32 is activated to shift the crankshaft 29' (in a clockwise direction as viewed in FIG. 6) sufficiently far that the accumulator pistons 42, 42' pass their top dead center positions--i.e., when accumulator cylinder 44 is pivoted slightly in a counterclockwise direction about its pivot point 50 and cylinder 44' is pivoted slightly in a counterclockwise direction about its pivot point 50'--the two accumulator pistons 42, 42' are free to operate in unison to drive the crankshaft 29' in a clockwise direction. This arrangement serves to balance the torsional forces imparted to the crankshaft 29 and renders the apparatus 55 considerably smoother in operation.
Turning next to FIGS. 7 and 8, a still further modified form of cutting apparatus embodying features of the present invention and generally illustrated at 56 has been shown. In this exemplary apparatus, as in the forms of the invention previously described in connection with FIGS. 5 and 6, a pair of identical "accumulator" piston/cylinder combinations 42/44 and 42"/44" are employed; but, unlike the forms of the invention shown in FIGS. 5 and 6 wherein the two accumulators are operated in phase, in FIGS. 7 and 8 they are operated out of phase so as to establish two sequential unidirectional power cutting strokes during successive 180° rotational increments of the driven crankshaft 29". Thus, as best shown in FIG. 7, it will be noticed that piston 42 is shown at its top dead center position with the gaseous or other expandable fluid medium contained within chamber 45 being fully compressed in readiness for driving crankshaft 29" through a 180° power cutting stroke. At the same time, however, piston 42" is in its bottom dead center position, with the gaseous or other fluid medium contained within chamber 45" having been fully expanded during the prior 180° cutting stroke. It will, therefore, be understood from the preceding discussion that as the positioning piston 31 continues to advance in its positioning cycle--as a result of pressurization of chamber 38 in positioning cylinder 32--the accumulator piston 42 will pass its top dead center position; and, at that instant the compressed gaseous medium within chamber 45 rapidly expands, serving to rapidly drive the piston 42 to the right as viewed in FIG. 7 and initiating powered rotation of driven crankshaft 29" in a clockwise cutting stroke as viewed in FIG. 8.
During the initial portion of the powered cutting stroke--for example, as the crankshaft 29" and blade 22" are driven through a rotational cutting angle of about 135°--piston 42" associated with the second accumulator 42"/44" moves to the left as viewed in FIG. 7 from its bottom dead center position, thus recompressing the gaseous medium within cylinder chamber 45". When the crankshaft 29" and blade 22" have moved through a powered cutting angle of about 90°, the pressure of the gaseous medium undergoing compression in chamber 45" and the expanding gaseous medium in chamber 45 will be substantially equal; but, the inertial forces generated by the crankshaft 29" and blade 22" during the rapid power cutting stroke serve to continue to drive the shaft 29" and blade 22 through an additional angle of approximately 45°. At that point in the operational cycle, the inertial forces are fully dissipated and the gaseous medium within chamber 45" is at a considerably higher pressure than that within chamber 45. However, the crankshaft 29" and blade 22" are precluded from rotating in a reverse direction--i.e., counterclockwise as viewed in FIG. 8--by the one-way clutch 41. The positioning piston/cylinder combination 31/32 is now manually operated in the manner previously described to continue powered clockwise rotation of the crankshaft 29" and blade 22" until such time as piston 42 is in its bottom dead center position and piston 42" is in its top dead center position. Continued movement of the positioning piston 31 now serves to shift accumulator piston 42" past its top dead center position, thus enabling accumulator 42"/44" to initiate a second power cutting stroke of approximately 135° wherein the gaseous medium within chamber 44" rapidly expands and the expanded gaseous medium within chamber 44 is partially recompressed.
Those skilled in the art will, therefore, appreciate that in the embodiment of the invention described in FIGS. 1 through 6, the accumulator(s) serve(s) to drive the crankshafts 29, 29' and blade 22 through a powered cutting stroke of approximately 180° with inertial forces powering the rotatable components through an additional angle on the order of approximately 90°, at which point the apparatus is repositioned for a subsequent identical cutting stroke; whereas in the embodiment of the invention shown in FIGS. 7 and 8, a first accumulator 42/44 drives the crankshaft 29" and blade 22" through a power driven cutting angle of approximately 90° with inertial forces carrying the rotatable components through an additional angle of about 45°, and after repositioning, the second accumulator 42"/44" serves to power the rotatable components through an identical cutting stroke.
In all of the embodiments of the invention herinabove described, the drive shafts 29, 29', 29" and blades 22, 22" are driven unidirectionally through rotational cutting angles. However, in its broader aspects, those skilled in the art will appreciate that the invention is not limited to such arrangements. Thus, merely by way of example, the accumulator pistons could, if desired, be coupled directly to a suitable cutting blade which is constrained from movement in a linear path (not shown). Alternatively, the apparatus can be designed so as to move the cutting blade through a pendulous or oscillatory cutting path--e.g., in the manner shown in FIGS. 9 through 10C.
To this end, and as best illustrated by reference first to FIGS. 9 and 10A conjointly, it will be observed that there has been illustrated a modified cutting apparatus, generally indicated at 58, wherein the accumulator piston 42 is not coupled directly to crankshaft 29 as in the previous embodiments, but, rather, the piston 42 is coupled to one end of a bifurcated arm 59 splined or otherwise non-rotatably mounted on a shaft 60 journaled for rotation in housing 61 and having a cutting blade 22 rigidly secured thereto for rotation in unison with shaft 60 and arm 59. In carrying out this aspect of the invention, the opposite end of bifurcated arm 59 is coupled to the crankshaft 29 by means of a connecting rod 62.
In operation, the various components of the apparatus 58 are initially in the relative positions shown in FIG. 10A wherein accumulator piston 42 is slightly past its top dead center position tending to drive the arm 59, shaft 60 and blade 22 in a clockwise direction (as viewed in the drawings) through a powered cutting stroke; but, such operation is inhibited by the one-way clutch 30 which permits rotation of crankshaft 29 only in a counterclockwise direction. As shown in FIG. 10A, crankshaft 92 is positioned just short of its top dead center position; and, consequently, the apparatus 58 is in readiness for a cutting operation upon initiation of such operation by user actuation of the positioning piston/cylinder combination 31/32 in the manner previously described.
Thus, to initiate a cutting operation, the user manipulates the handle mounted control valve on the apparatus (not shown in FIG. 10A, but similar to the valve 40 shown in FIG. 1) so as to pressurize chamber 38 in positioning cylinder 32. As a consequence, positioning piston 31 moves downwardly from the solid line position shown in FIG. 10A (the dotted line position shown at 31 in FIG. 10B) towards the solid line position 31a shown in FIG. 10B, thus rotating crankshaft 29 in a counterclockwise direction from the solid line position shown in FIG. 10A (the dotted line position 29 shown in FIG. 10B) to the solid line position 29a shown in FIG. 10B where the crankshaft 29 is in its top dead center position. It will, of course, be appreciated that as the crankshaft 29 moves towards its top dead center position shown at 29a in FIG. 10B, the connecting rod 62 serves to rotate the bifurcated arm 59 in a counterclockwise direction about the axis of shaft 60, thus serving to shift the accumulator piston 42 to its top dead center position and, at the same time, rotating blade 22 slightly in a counterclockwise direction.
As the positioning piston 31 continues to move downwardly towards the position shown in solid lines at 31b in FIG. 10C, crankshaft 29 moves past top dead center; and, as a consequence, connecting rod 62 serves to rotate arm 59 in the reverse direction--i.e., clockwise as viewed in FIGS. 10A through 10C--back towards and through the position shown in FIG. 10A. At this point in the operational cycle, since both crankshaft 29 and accumulator piston 42 are positioned slightly past top dead center, one-way clutch 30 no longer inhibits clockwise rotation of the bifurcated arm 59 and, therefore, the compressed gaseous medium or other source of stored potential energy within cylinder 44 is permitted to rapidly expand, shifting actuator piston 42 upwardly from the position shown in FIG. 10B towards that shown in FIG. 10C, thus driving the arm 59 and cutting blade 22 rapidly through a powered cutting stroke of approximately 60°. Once again, inertial forces generated serve to power the crankshaft 29 past its bottom dead center position shown in FIG. 10C, thus initiating counterclockwise rotation of crankshaft 29 and blade 22 and partially recompressing the fully expanded potential energy storage medium within accumulator cylinder 44. During the power driven cutting stroke of the blade 22, the operator is free to reverse the outlet/inlet ports 34/35 associated with positioning cylinder 32 so as to pressurize chamber 36 and shift piston 31 upwardly from the position shown in FIG. 10C towards that shown in FIG. 10A, thus rotating the outer shell of one-way clutch 30 and again preparing the apparatus 58 for a further cutting operation. At such time as the outer shell of one-way clutch 30 is being repositioned, one-way clutch 40 (FIG. 9) precludes clockwise movement of crankshaft 29.
Once the movable components of the apparatus 58 again reach the approximate position shown in FIG. 10A, arm 59 engages limit switch 51, thus temporarily inhibiting the flow of pressurizing fluid medium to positioning cylinder 32 and causing the operating components of the cutting to dwell in such position until the operator of the equipment again overrides the dwell mechanism to start another cutting cycle by again causing the positioning piston/cylinder combination 31/32 to shift crankshaft 29 towards and through its top dead center position as shown in FIG. 10B.
Referring next to FIGS. 11 and 12, yet another slightly modified form of cutting apparatus, generally indicated at 64, has been illustrated which, although embodying the features of the invention heretofore described, requires only a single one-way clutch 30 and which avoids the need for employing a second one-way clutch such as that shown at 41 in FIGS. 1 through 9. To this end, the apparatus 64 includes a housing 65 within which crankshaft 29 is journaled for rotation with one end of the crankshaft 29 being received within positioning one-way clutch 30 and cutting blade 22 splined or otherwise drivingly connected to the opposite end of the crankshaft. As in the previous embodiment of the invention, an accumulator 42/44 is used to store potential energy for driving the crankshaft 29 and cutting blade 22--this time, in a counterclockwise direction as viewed in FIG. 12--when the accumulator piston 42 passes slightly beyond its top dead center position; and, a positioning piston/cylinder combination 31/32 is used to power the crankshaft 29 through one-way clutch 30 so as to rotate the crankshaft 29 towards and through its top dead center position. However, rather than employing a second one-way clutch to prevent rotation of the operating components during repositioning of the outer shell of clutch 30, the exemplary apparatus 64 includes a spring-biased latch 66 for preventing clockwise rotation of the blade 22 and shaft 29 when the accumulator 42/44 is located just to the right of top dead center as viewed in FIG. 12. Thus, with the operating component of apparatus 64 in the position shown in FIG. 12, it is merely necessary to retract piston 31 so as to shift the one-way clutch 30 in a counterclockwise direction, thereby rotating crankshaft 29 in a counterclockwise direction and moving the accumulator piston 42 towards and through its top dead center position. At this point, the compressed gaseous medium or other source of stored potential energy within accumulator cylinder 44 is allowed to rapidly expand, driving the crankshaft 29 and cutting blade 22 rapidly through a counterclockwise cutting stroke. At such time as the accumulator piston 42 reaches the bottom of its expansion power cutting stroke, inertial forces generated by the crankshaft 29 and blade 22 serve to continue the counterclockwise rotation thereof, thus partially recompressing the expanded gaseous medium within cylinder 44. When the inertial forces developed are fully dissipated, one-way clutch 30 serves to preclude reverse or clockwise rotation of the shaft 29 and blade 22. At this point in the operating cycle, the positioning piston 31 is retracted so as to complete the counterclockwise rotation of the moving components, with the raised end 67 of blade 29 serving to cam the spring-biased latch to the left as viewed in FIG. 12, permitting the blade end 67 to pass the latch 66 which then snaps back under the biasing force exerted by spring 68 to prevent clockwise rotation of the blade and shaft. Such movement of the latch 66 is sensed by a suitable limit switch 51 which serves to deactivate the positioning piston/cylinder combination 31/32 when the components reach the positions shown in FIG. 12, thus allowing the user to reposition the outer shell of one-way clutch 30 while latch 66 prevents reverse or clockwise rotation of blade 22 and shaft 29.
Thus, those skilled in the art will appreciate that there have herein been disclosed various forms of cutting apparatus embodying features of the invention which are characterized by their simplicity, ruggedness, compactness and reliability in operation; and, wherein means are provided for storing potential energy in piston/cylinder type accumulators in which the accumulator is disabled until such time as it reaches its top dead center position with the gaseous medium or other source of stored potential energy being fully compressed. At that point in the operating cycle, the accumulator is enabled, allowing the fully compressed potential energy storage medium to rapidly expand so as to drive a suitable cutting blade coupled to the accumulator piston through a powered cutting stroke. Inertial forces developed during the powered cutting stroke serve to partially recompress the expanded gaseous medium or other potential energy storage means; and, when such interial forces are fully dissipated, a one-way positioning mechanism serves to prevent reverse movement of one or more of the movable components while the accumulator piston is being repositioned at its top dead center position with the potential energy storage medium contained within the accumulator cylinder being fully compressed and ready for the next cutting cycle. | A simple, rugged, compact and reliable apparatus (20, 54, 55, 56, 58, 64) for cutting trees (24), vegetation and other objects, together with methods for operating such apparatus, are provided wherein a cutting blade (22, 22"), constrained for movement along a cutting path generally transverse to the tree (24) or other object being cut, is coupled to a piston/cylinder type accumulator (42/44, 42'/44', 42"/44") within which a compressible medium defines a source of stored potential energy. In the various embodiments shown, the accumulator is disabled until such time as its piston (42, 42', 42") is shifted past its top dead center position so as to fully compress the compressible medium contained therein for maximizing the amount of stored potential energy; and, a positioning mechanism comprising a second piston/cylinder combination (31/32) is provided for selectively shifting the accumulator piston (42, 42', 42") towards and past its top dead center position so as to permit the fully compressed potential energy storage medium to rapidly expand and, through the accumulator piston, drive the cutting blade (22, 22") through its cutting patch with inertial forces generated by the driven components serving to partially recompress the compressible potential energy storage medium upon completion of the cutting stroke, and wherein the positioning mechanism is used to return the accumulator piston (42, 42', 42") to its top dead center position upon dissipation of the inertial forces and thus completing the compression of the compressible medium preparatory to the next cutting stroke. One-way clutches (30, 41) and/or a latching mechanism (66, 68) are employed to control movement of the driven components. | 0 |
RELATED APPLICATIONS
[0001] This application claims priority to, and is a continuation of International Application No. PCT/GB2007/001544 having an International filing date of Apr. 25, 2007, which is incorporated herein by reference, and which claims priority to Great Britain Patent Application No. 0608352.1 filed Apr. 28, 2006.
BACKGROUND/SUMMARY
[0002] This invention relates to the treatment of contaminated liquid by contact with an adsorbent material. The invention has particular, but not exclusive application in the treatment of liquids to remove organic pollutants. Although the invention has particular use in the anodic oxidation of organic compounds, it can also be used for the cathodic reduction of compounds. It can also be used for disinfection.
[0003] Adsorbent materials are commonly used in liquid treatment apparatus. Carbon-based such materials are particularly useful, and are capable of regeneration by the passage of an electric current therethrough. The use of carbon-based adsorbents in the treatment of contaminated water is described in the following papers published by The University of Manchester Institute of Science and Technology (now the University of Manchester) in 2004, incorporated herein by reference:
[0004] Electrochemical regeneration of a carbon-based adsorbent loaded with crystal violet dye by N W Brown, E P L Roberts, A A Garforth and R A W Dryfe Electrachemica Acta 49 (2004) 3269-3281
[0005] Atrazine removal using adsorption and electrochemical regeneration by N W Brown, E P L Roberts, A Chasiotis, T Cherdron and N Sanghrajka Water Research 39 (2004) 3067-3074
[0006] The present invention is directed at apparatus for exploiting the ability of the use of an adsorbent material capable of regeneration in the treatment of contaminated liquid. According to the invention, apparatus for treating liquid by contact with a particulate adsorbent material, comprises a reservoir having an inlet and an outlet for liquid to be treated, with a regeneration chamber within the reservoir. Means are provided for recycling adsorbent material along a path including passage through the regeneration chamber and in a body of liquid in the reservoir. The regeneration chamber is defined between two electrodes for coupling to a source of electrical power. In use, a voltage can be applied between the electrodes, either continuously or intermittently, to pass current through the adsorbent material and regenerate it in the manner described in the papers referred to above. The adsorbent material is typically carbon-based.
[0007] The treatment and regeneration process can be continuous or semi-continuous. An individual volume of liquid can be treated as a batch, with the adsorbent material being regenerated as the respective batch is treated, or between batch treatments. Some compounds may also be treated within an undivided cell, provided there is no continuous electrical connection between the cathode and anode through the solid conducting adsorbent material. In a continuous or semi-continuous process the flow rate of the liquid through the apparatus is determined and controlled to ensure a sufficient dwell time in contact with the recycling adsorbent.
[0008] Apparatus of the invention can be used with a single regeneration chamber, or with a plurality of regeneration chambers in more substantial equipment. Such a plurality of chambers can be in the form of a bank mounted in a common reservoir, which can accommodate circulation of adsorbent material only from either side of the chambers with the chambers closely aligned along an axis of the reservoir and extending to opposing end walls of the reservoir. In another arrangement the bank can accommodate circulation from the sides and ends of a bank of closely aligned chambers within the reservoir and spaced from its end walls. In yet another arrangement circulation can be from around the periphery of each chamber spaced from adjacent chambers in the reservoir. The use of a common reservoir in this way facilitates the recycling of adsorbent material and the flow of liquid through the equipment in greater quantities. A common inlet and outlet can be used for the liquid to be treated, and a single system can be used to recycle the adsorbent. Although the chambers are arranged in a bank, individual electrodes will normally be associated with each chamber for regeneration of the adsorbent.
[0009] In apparatus according to the invention, the adsorbent material can be recycled along a variety of different paths, at least a part of which will coincide with the path of liquid to be treated through the reservoir. In that part, the liquid and adsorbent can pass in either the same or the opposite direction. Normally, contaminated liquid will be delivered at the base of the reservoir, and discharged from an upper location, while the adsorbent material follows at least one continuous path within the reservoir.
[0010] Recycling of the adsorbent is most easily accomplished by delivery of air to the base or one or more sections of the path which carry the material upwards in that section or sections. This movement carries the material over a boundary at the top of the regeneration chamber, in which it then falls under gravity. As it moves through the regeneration chamber, the applied voltage causes a current to flow through the material, destroying the adsorbed pollutants. The breakdown products can be released in gaseous form, and treated separately as appropriate.
[0011] The use of air to recycle the adsorbent material is of course beneficial in itself to the treatment process. It aerates the contaminated liquid, as well as agitating the adsorbent material as it is recycled, thereby enhancing its exposure to the contaminated liquid. Incoming liquid can also be used to entrain and assist in circulating the adsorbent from the bottom of the regenerating chamber. This can be of benefit when treating liquids containing surface active compounds which could result in foaming. Of course, different fluids can be used to accomplish different treatments of various liquids in the apparatus.
[0012] The recycling path for the adsorbent material and the regeneration chamber can be arranged differently in a reservoir, depending on the requirements for liquids to be treated, contact time of liquids to be treated and the amount of material to which the liquid should be exposed. In a preferred arrangement, the regeneration chamber is located centrally within a reservoir, with the adsorbent material being adapted to fall through it, and be recycled upwardly within the reservoir and through the liquid to be treated on the outside of the chamber, A convenient design of apparatus has the regeneration chamber located between two treatment chambers, one on either side thereof, in what is effectively a two-dimensional arrangement. The electrodes for the regeneration chamber can then be disposed on opposite faces thereof, these faces being different from the sides against which the treatment chambers are defined. This arrangement can though, of course be extended to three-dimensions with the regeneration chamber being surrounded by a plurality of treatment chambers. These arrangements can also be reversed, with a single treatment chamber located centrally either within an annular regeneration chamber, or surrounded by an array of regeneration chambers.
[0013] Adsorbent materials suitable for use in this invention are electrically conducting solid materials capable of easy separation from the liquid phase. The material may be used in powder, flake or granular form. Whilst the particle size is not critical, the optimum size will depend on the adsorbent properties. The material used and particularly the particle size is a compromise between surface area, electrical conductivity and ease of separation. Preferred materials are graphite intercalation compounds (GICs). A particularly preferred GIC is a bi-sulphate intercalated product.
[0014] It can be formed by chemically or electrochemically treating graphite flakes in oxidising conditions in the presence of sulphuric acid. However a large number of different GIC materials have been manufactured and different materials will have different adsorptive properties which will be a factor in selecting a particular material.
[0015] Reducing the particle size of the adsorbent material will significantly increase the surface area available for adsorption. However reducing the particle size will make separation of the solid phase more difficult. in the practice of the invention a typical particle size is 0.25-0.75 mm. Very fine particles (<50 microns) can be used as the adsorbent material as these can be separated from the liquid phase easily if an organic polymer is used as a flocculent. This organic flocculent is then destroyed by regeneration. The use of other materials of lower electrical conductivity and density would benefit from larger particles.
[0016] The higher the electrical conductivity of the adsorbent material, the lower will be the voltage required across the cell and so the lower power consumption. Typical individual GIC particles will have electrical conductivities in excess of 10,000 Ω −1 cm −1 . However in a bed of particles this will be significantly lower as there will be resistance at the particle/particle boundary. Hence it is desirable to use as large a particle as possible to keep the resistance as low as possible. Hence a bed of fine wet particles has been shown to have an electrical conductivity of 0.16 Ω−1cm −1 compared with 0.32 Ω −1 cm −1 for a bed of larger particles. As a comparison a bed of granular and powdered activated carbon would typically have electrical conductivities of 0.025 and 0.012 Ω −1 cm −1 respectively.
[0017] The preferred GIC used in the practice of the invention is in flake form, and typically has a composition of at least 95% carbon, and a density of around 2.225 g cm −3 . However flake carbons can be used as the starting materials for producing GICs with significantly lower carbon contents (80% or less). These compounds can also be used within the cell, but are likely to result in slightly higher voltages across the electrochemical regeneration stage. Other elements will also be present within the GIC, these compounds are dependent on the initial composition of the flake graphite and the chemicals used to convert the flakes into intercalated form. Different sources of graphite can produce GICs with different adsorptive properties.
BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWINGS
[0018] Embodiments of the invention will now be described by way of example and with reference to the accompanying schematic drawings wherein;
[0019] FIG. 1 is a vertical cross-section through apparatus according to a first embodiment of the invention;
[0020] FIG. 2 is a horizontal cross-section taken on line A-A of FIG. 1 ; and
[0021] FIG. 3 is a perspective, partly broken view illustrating a second embodiment of the invention.
DETAILED DESCRIPTION
[0022] The drawings show a reservoir 2 of generally rectangular cross-section defined by front and rear walls 4 and 6 , and side walls 8 . Within the reservoir, inner walls 10 define a regeneration chamber that extends the whole width of the reservoir between the front and rear walls 4 and 6 ( FIG. 2 ). The base of the regeneration chamber is defined by convergent walls 12 , which form an opening 14 for the discharge of particulate adsorbent material 16 from the regeneration chamber. Upper walls 18 define a central zone over the regeneration chamber.
[0023] When the apparatus is ready for use, an adsorbent material is loaded into the regeneration chamber 10 in the required amount. Liquid to be treated is then delivered to the reservoir through inlets 20 , and filled to a level just below that of the discharge outlet 22 between the upper walls 18 . Air under pressure is then delivered through openings in the base of the reservoir as indicated at 24 . This generates bubbles in the liquid, and draws particulate adsorbent material from below the opening 14 at the bottom of the regeneration chamber, and carries it upward through treatment chambers 26 defined in the reservoir between the respective walls 8 and 10 . As the adsorbent material is carried upwards through the liquid, it absorbs pollutants in the liquid. The rising air carries the adsorbent material around and over the top of the walls 10 , where it is directed by the wails 18 back into the regeneration chamber. Obstacles 28 and 30 are installed at the top of the regeneration chamber to control the flow of the solid, liquid and gaseous phases in the reservoir. They can break up any coagulated particles and guide them into the chamber. They also serve to discourage adsorbent particles from entering the zone between the walls 18 , from which treated liquid is discharged, and prevent bubbles generated in the bed of adsorbent materials in the regeneration chamber from entering this zone.
[0024] Liquid to be treated is delivered to the reservoir through the inlets 20 at a flow rate selected to match its required residence time in the reservoir and contact with the adsorbent material sufficient to enable absorption of pollutants therefrom. Its general flow is upwards through the reservoir, and it is discharged by overflow through the port 22 . It will be noted that the liquid can only reach the discharge port 22 by upward flow from the top of the regeneration chamber, between the walls 18 . The walls 18 thus define a quiescent zone protected from movement generated by the air bubbling through the liquid in the treatment chambers.
[0025] While a generally upward flow of liquid to be treated is preferred, the opposite arrangement can also be used. Thus, liquid to be treated could be admitted at ports indicated at 32 , and withdrawn from discharge points 34 . Some form of filter would be required at the discharge points because of the proximity of the adsorbent material, but the air flowing upwards from the reservoir base should prevent blockages. The direction of flow of liquid through the reservoir will of course be selected on the basis of the system requirements, but there may be some benefit in having the flow of liquid generally opposite to the flow of adsorbent material in the treatment chambers. That would be case if the general direction of flow of liquid in the reservoir was downwards rather than upwards.
[0026] As noted above, the apparatus may be used for the separate treatment of individual volumes of liquid. In this variant, the reservoir is filled with liquid to the required level, and the adsorbent material recycled through the regeneration chamber for a period of time appropriate to complete the treatment. The liquid is then removed, for example by drainage from discharge port 34 , and a fresh charge of liquid delivered to the reservoir. The adsorbent material will normally be regenerated while it is recycled during the treatment process.
[0027] In apparatus of the invention, the adsorbent material is continuously or intermittently regenerated while it passes through the regeneration chamber in its recycling path. This is accomplished by the application of an electrical voltage between an anode 36 and a cathode 38 disposed on opposite faces of the chamber 16 . Pollutants are released by the regenerating adsorbent material in gaseous form, from the top of the reservoir. These released gases can be discharged to the atmosphere, but can of course be subject to separate treatment if required. The cathode is housed in a separate compartment 42 defined by a conductive membrane 40 . This enables a catholyte to be pumped through the compartment, and the membrane protects the cathode from direct contact with the adsorbent material.
[0028] The purpose of the membrane 40 is to prevent the solid adsorbent particles coming into contact with the cathode 38 as this could result in the electrons going direct from cathode 38 to anode 36 without passing through the aqueous phase. In this case there would be no organic oxidation and no regeneration of the adsorbent. The membrane 40 must allow the transfer of ions or electrons through it to complete the electric circuit. However, this introduces an additional resistance into the system. Such membranes also only operate well at certain pH levels. In this case the oxidation of the water on the anode side (giving acid conditions) and reduction of water on the cathode side (giving alkali conditions) necessitates pH adjustment to keep the membrane functioning with an acceptable voltage. In practice this requires the catholyte to be monitored and adjusted to keep it acidic, for example by the constant addition of acid, which is undesirable, the pumping of catholyte through the cathode compartments, and suitable pH monitoring and adjustment equipment involving tanks, pumps and probes, which incurs further capital, operational′ and maintenance costs.
[0029] An alternative to the use of a conductive membrane is to use a porous filter. This would prevent the contact of the solid with the cathode, but allow the passage of. water and ions. The constant reduction of water at the cathode would result in the catholyte becoming more alkaline, giving a higher conductivity and lower cell voltages.
[0030] FIG. 3 illustrates a second embodiment of the invention in which a plurality of regeneration chambers 44 are mounted in the form of a bank 46 in a reservoir 48 . The chambers 44 are closely aligned, and extend to opposing end walls 50 of the reservoir (only one end wall is shown). The walls 52 of the regeneration chambers extend upwards and laterally from the chambers themselves in the form of plates 54 which assist in guiding the circulating mixture of particles and liquid into the regeneration chambers. Additional walls 56 are provided as further guides for the recirculating mixture, and define a quiescent zone from which liquid is discharged by overflow through the outlet port 58 .
[0031] Circulation of the adsorbent material in the mixture is achieved by the delivery of air under pressure to conduits 60 on either side of the bank 46 . Air is released from openings (not shown) in the conduits 60 , which rises upward and along the external surface of the plates 54 . Additional plates 62 can be fitted to guide the particulate material back towards the entrance to the bank 46 of regeneration chambers 44 , between the plates 54 and walls 56 .
[0032] The liquid to be treated is introduced into the reservoir 48 through ducts 64 . A plurality of outlets from the duct into the reservoir can be used. It will be appreciated that the actual and relative orientation of the conduits 60 and ducts 64 within the reservoir can be selected as the size, location and orientation of the plates and walls 54 , 56 and 62 , in order to achieve the desired circulation of the adsorbent material.
[0033] In the arrangement illustrated in FIG. 3 , the regeneration, chambers 44 are aligned closely together, substantially in contact with one another and with the end chambers substantially abutting against an end wall of the reservoir 48 . This arrangement results in a predictable movement of the adsorbent material, in generally circular paths on either side of the reservoir axis. However, there can be some merit in creating gaps between the regeneration chambers to enable some adsorbent material to recirculate without passing through the regeneration chamber. In yet another arrangement the regeneration chambers need not be aligned, but rather be individually mounted in different locations within the reservoir.
[0034] In the apparatus illustrated in FIG. 3 , the adsorbent material is regenerated while it passes through each regeneration chamber in its recycling path, generally as described above with reference to FIG. 2 . The anode and cathode will though, normally be disposed at the lower end of the regeneration chamber side walls 52 to avoid interference with regeneration in adjacent chambers. | Apparatus for treating liquid by contact with a particulate adsorbent material comprises a regeneration chamber ( 10 ) within a reservoir ( 2 ) for liquid to be treated. Adsorbent material is recycled along a path including passage through the regeneration chamber ( 10 ) and in a body of liquid in the reservoir to contact and treat the liquid. The adsorbent material is capable of regeneration, and the regeneration chamber ( 10 ) is defined between two electrodes ( 36, 38 ), which can be coupled to a source of electrical power. The treatment process can be continuous with liquid flowing through the reservoir while the adsorbent material is recycled and regenerated. Alternatively, individual quantities of liquid may be treated on a batch basis. A plurality of regeneration chambers may be arranged within a common reservoir, such as in a bank of chambers aligned along an axis thereof. | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a variable-reactance circuit which comprises bipolar transistors.
2. Description of the Related Art
FIG. 1 shows a conventional VCO (Voltage-Controlled Oscillator), which is disclosed in Jpn. Pat. Appln. KOKAI Publication No. 6-303089, laid open Oct. 28, 1994.
As shown in FIG. 1, the VCO has an oscillator 51 and a variable-reactance circuit 52. The oscillator 51 comprises npn bipolar transistors Q11 and Q12, a constant-current source I11, a reference-voltage source V and a resonator 12. The components of the oscillator 51 are connected as will be indicated below.
The constant-current source I11 is connected between the emitter node of the transistors Q11 and Q12 and a power-supply terminal 10a. A low potential, e.g., the ground potential GND, is applied to the power-supply terminal 10a. The collector of the transistor Q11 is connected to a power-supply terminal 10b, to which a high potential VCC is applied. The base of the transistor Q11 is connected to the collector of the transistor Q12. The reference-voltage source V is connected between the base of the transistor Q12 and the power-supply terminal 10a. The resonator 12 is connected between the collector of the transistor Q12 and the power-supply terminal 10b. Through the collector of the transistor Q12 there is supplied the output signal OUT of the VCO is supplied.
The variable-reactance circuit 52 comprises npn bipolar transistors Q1 to Q6, constant-current sources I1 and I2, a capacitor C1, diodes D1 and D2 and variable-current sources Iv1 and Iv2. The components of the oscillator 51 are connected as will be described below.
The constant-current source I1 is connected between the emitter of the transistor Q1 and the power-supply terminal 10a, and the diode D1 between the collector of the transistor Q1 and the power-supply terminal 10b. The constant-current source I2 is connected between the emitter of the transistor Q2 and the power-supply terminal 10a, and the diode D2 between the collector of the transistor Q2 and the power-supply terminal 10b. The capacitor C1 is connected between the emitter of the transistor Q1 and the emitter of the transistor Q2.
The variable-current source Iv1 is connected between the emitter node of the transistors Q3 and Q4 and the power-supply terminal 10a. The output current of the variable-current source Iv1 is controlled by a control signal supplied to a control terminal 11a. The variable-current source Iv2 is connected between the emitter node of the transistors Q5 and Q6 and the power-supply terminal 10a. The output current of the variable-current source Iv1 is controlled by a control signal supplied to a control terminal 11b.
The base of the transistors Q3 is connected the collector of the transistor Q1 and the base of the transistor Q2. So is the base of the transistor Q6. The bases of the transistors Q4 and Q5 are connected to the collector of the transistor Q2. The collectors of the transistors Q3 and Q5 are connected to the power-supply terminal 10b. The collectors of the transistors Q4 and Q6 are connected to the base of the transistor Q1. The base of the transistor Q1 is connected to the collector of the transistor Q12 of the oscillator 51.
The reactance as viewed from the output terminal 13 of the VCO varies with the value of the control signals applied to the control terminals 11a and 11b, i.e., the values of the currents supplied from the variable-current sources Iv1 and Iv2. Hence, the control signals applied to the control terminals 11a and 11b change the frequency of the signal OUT generated by the VCO.
In the VCO described above, the variable-reactance circuit 52 can operate when the voltage applied between the power-supply terminals 10a and 10b is equal to or higher than the sum of the voltage (about 0.7 V) applied between the base of the transistor Q3 and the emitter of the transistor Q5 and the forward voltage drop (about 0.7 V) at the diode D1. However, the voltage applied to the system (LSI) including the VCO is too low. Therefore, the power-supply potential VCC, i.e., the power-supply voltage, needs to be 1 V or less if the ground potential GND is applied to the power-supply terminal 10a.
SUMMARY OF THE INVENTION
The present invention has been made in view of the foregoing. The object of the invention is to provide a variable-reactance circuit which can operate correctly even if the power-supply potential is equal to or less than 1 V.
To achieve the object, a variable-reactance circuit according to this invention comprises: a first bipolar transistor having a base, an emitter connected to a first power-supply terminal by a first resistor, and collector connected to the base and also to a second power-supply terminal by a first constant-current source; a second bipolar transistor having an emitter connected to the first power-supply terminal by a second resistor, a base connected to the base of the first bipolar transistor, and a collector connected to the second power-supply terminal by a second constant-current source; a third bipolar transistor having an emitter connected to the emitter of the first bipolar transistor, a base connected to the collector of the second bipolar transistor, and a collector connected to the second power-supply terminal by a third constant-current source and also to the second power-supply terminal by a third resistor and a fourth constant-current source; a diode having a cathode connected to the first power-supply terminal by a fourth resistor and an anode connected to the fourth constant-current source; a fourth bipolar transistor having an emitter connected to the first power-supply terminal by a first variable-current source, a base connected to the collector of the third bipolar transistor, and a collector connected to the second power-supply terminal; a fifth bipolar transistor having an emitter connected to the first power-supply terminal by the first variable-current source, a base connected to the collector of the first bipolar transistor, and a collector which is to be connected to an output node of an oscillator; a sixth bipolar transistor having an emitter connected to the first power-supply terminal by a second variable-current source, a base connected to the collector of the third bipolar transistor, and a collector connected to the output node of the oscillator; a seventh bipolar transistor having an emitter connected to the first power-supply terminal by the second variable-current source, a base connected to the collector of the first bipolar transistor, and a collector connected to the second power-supply terminal; and a capacitor connected at one end to the emitter of the first bipolar transistor and connected at the other end to the output node of the oscillator.
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 learned by practice of the invention. The objects and advantages of the invention may be realized and obtained by means of the instrumentalities and combinations particularly pointed out in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate presently preferred embodiments of the invention and, together with the general description given above and the detailed description of the preferred embodiments given below, serve to explain the principles of the invention.
FIG. 1 is a circuit diagram of a VCO incorporating a conventional variable-reactance circuit;
FIG. 2 is a circuit diagram of a VCO incorporating a variable-reactance circuit according to a first embodiment of the present invention;
FIG. 3 is a circuit diagram of a VCO incorporating a variable-reactance circuit according to a second embodiment of the invention;
FIG. 4 is a circuit diagram of a VCO incorporating a variable-reactance circuit according to a third embodiment of this invention;
FIG. 5 is a circuit diagram of a VCO incorporating a variable-reactance circuit according to a fourth embodiment of the present invention; and
FIG. 6 is a circuit diagram of a VCO incorporating a variable-reactance circuit according to a fifth embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Variable reactance circuits according to this invention will be described in detail, with reference to the accompanying drawings.
FIG. 2 shows a VCO which incorporates a variable-reactance circuit according to the first embodiment of the invention. As seen from FIG. 2, the VCO has an oscillator 51 and a variable-reactance circuit 52.
The oscillator 51 comprises npn bipolar transistors Q11 and Q12, a constant-current source I11, a reference-voltage source V, and a resonator 12. The components of the oscillator 51 are connected as will be described below.
The constant-current source I11 is connected between the emitter node of the transistors Q11 and Q12 and a power-supply terminal 10a. A low potential, for example the ground potential GND, is applied to the power-supply terminal 10a. The collector of the transistor Q11 is connected to a power-supply terminal 10b, to which a high potential VCC is applied. The base of the transistor Q11 is connected to the collector of the transistor Q12. The reference-voltage source V is connected between the base of the transistor Q12 and the power-supply terminal 10a. The resonator 12 is connected between the collector of the transistor Q12 and the power-supply terminal 10b. Through the collector of the transistor Q12 there is supplied the output signal OUT of the VCO is supplied.
The variable-reactance circuit 52 comprises a capacitor C11, an amplifying section 21, and differential sections 22 and 23. The amplifying section 21 comprises npn bipolar transistors Q21 to Q23, constant-current sources I21 to I24, resistors R1 to R4, and a diode D3. The first differential section 22 comprises npn bipolar transistors Q24 and Q25 and a variable-current source Iv1. The second differential section 23 comprises npn bipolar transistors Q26 and Q27 and a variable-current source Iv2.
The components of the variable-reactance circuit 52 are connected as will be indicated below.
The resistor R1 is connected between the emitter of the transistor Q21 and the power-supply terminal 10a. The constant-current source I21 is connected between the collector of the transistor Q21 and the power-supply terminal 10b. The base and collector of the transistor Q21 are connected to each other. The resistor R2 is connected between the emitter of the transistor Q22 and the power-supply terminal 10a. The constant-current I22 is connected between the collector of the transistor Q22 and the power-supply terminal 10b. The bases of the transistors Q21 and Q22 are connected to each other.
The constant-current source I23 is connected between the collector of the transistor Q23 and the power-supply terminal 10b. The base of the transistor Q23 is connected to the collector of the transistor Q22. The emitter of the transistor Q23 is connected to the emitter of the transistor Q21. The resistor R4 is connected to the power-supply terminal 10a, and the constant-current source I24 to the power-supply terminal 10b. The diode D3 is connected between the constant-current source I24 and the resistor R4. The diode D3 is composed of, for example, an npn bipolar transistor whose collector and base are connected together. The resistor R3 is connected between the collector of the transistor Q23 and the node C of the constant-current source I24 and the diode D3.
The variable-current source Iv1 is connected between the emitter node of the transistors Q24 and Q25 and the power-supply terminal 10a. The output current of the variable-current source Iv1 is controlled by a control signal supplied to a control terminal 11a. The variable-current source Iv2 is connected between the emitter node of the transistors Q26 and Q27 and the power-supply terminal 10a. The output current of the variable-current source Iv2 is controlled by a control signal supplied to a control terminal 11b.
The bases of the transistors Q24 and Q26 are connected to the collector (i.e., node B) of the transistor Q23. The bases of the transistors Q25 and Q27 are connected to the collector (i.e., node A) of the transistor Q21. The collectors of the transistors Q24 and Q27 are connected to the power-supply terminal 10b. The collectors of the transistors Q25 and Q26 are connected to the emitter of the transistor Q21 by the capacitor C11. The collectors of the transistors Q25 and Q26 are connected to the collector of the transistor Q12 incorporated in the oscillator 51. (The collector of the transistor Q12 serves as the output node 13 of the VCO.)
The reactance as viewed from the output node 13 of the VCO varies with the value of the control signals applied to the control terminals 11a and 11b, i.e., the values of the currents supplied from the variable-current sources Iv1 and Iv2. Hence, the control signals applied to the control terminals 11a and 11b change the frequency of the signal OUT from the VCO.
How the variable-reactance circuit shown in FIG. 2 operates will now be explained.
Assume that I1=I2=I3=I4=I and that R1:R2:R4=1:2:2. Here, I1, I2, I3 and I4 are the output currents of the constant-current sources I1, I2, I3 and I4, respectively, and R1, R2, R3 and R4 are the resistances of the resistors R1, R2, R3 and R4, respectively. In this case, a current (=I1+I3) flows through the resistor R1, and a current (=I4) flows through the resistor R4. Therefore, the voltage drop across the resistor R1 is (I1+I2)×R1 and the voltage drop across the resistor R4 is I4×R4.
Assuming that the current amplification factors of the transistors Q21 to Q27 are infinitely large, there is the relationship of: (I1+I3)×R1=I4×R4. Since the collector current of the transistor Q21 is equal to the forward current flowing through the diode D3, the potential of the collector (i.e., node A) of the transistor Q21 is equal to the potential of the anode (i.e., node C) of the diode D3.
Assume a signal Δv is supplied to the output node 13 of VCO. Then, the current Δi' flowing through the capacitor C11 is given as: ##EQU1## where C11 is the capacitance of the capacitor C11.
The current Δi' is amplified by the amplifying section 21 and the differential section 23. A current Δi flows toward the collectors of the transistors Q24 and Q26. The magnitude and direction of this current Δi changes, depending on the values of the currents which flow through the variable-current sources Iv1 and Iv2.
The relationship between currents Δi' and Δi can be expressed as follows:
Δi/Δi'=±Ai (2)
where Ai is the current gain of the variable-reactance circuit 52. The current gain Ai can be minutely adjusted by changing the resistance of the resistor R4.
The input impedance Zin of the variable-reactance circuit 52 is represented by: ##EQU2##
As can be understood from the equation (3), the reactance as viewed from the output node 13 changes as the input impedance Zin of the circuit 52 varies, depending upon the output currents of the variable-current sources Iv1 and Iv2. The frequency of the signal OUT from the VCO therefore changes in accordance with the control signals supplied to the control terminals 11a and 11b.
The variable-reactance circuit 52 can operate, provided that the power-supply voltage is equal to or higher than the voltage (about 0.7 V) between the base of the transistor Q24 and the emitter of the transistor Q26. In other words, the circuit 52 operates if a potential of 0.7 or more is applied to the power-supply terminal 10b while the ground potential GND is applied to the power-supply terminal 10a. Namely, the variable-reactance circuit 52 can reliably operate at a power-supply voltage of about 1 V.
FIG. 3 illustrates a VCO incorporating a variable-reactance circuit according to the second embodiment of the invention. As shown in FIG. 3, this VCO has an oscillator 51 and a variable-reactance circuit 52, too.
The oscillator 51 comprises npn bipolar transistors Q11 and Q12, a constant-current source I11, a reference-voltage source V, a resonator 12, and an inverter 14. The inverter 14 comprises an npn bipolar transistor Q28, resistors R11 and R12 and a constant-current source 15.
The components of the oscillator 51 are connected as will be described below.
The constant-current source I11 is connected between the emitter node of the transistors Q11 and Q12 and a power-supply terminal 10a. A low potential, for example the ground potential GND, is applied to the power-supply terminal 10a. The collector of the transistor Q11 is connected to a power-supply terminal 10b, to which a high potential VCC is applied. The base of the transistor Q11 is connected to the collector of the transistor Q12. The reference-voltage source V is connected between the base of the transistor Q12 and the power-supply terminal 10a. The resonator 12 is connected between the collector of the transistor Q12 and the power-supply terminal 10b. The emitter of the transistor Q28 is connected to the power-supply terminal 10a. The constant-current source 15 is connected between the collector of the transistor Q28 and the power-supply terminal 10b. The resistor R11 is connected between the base of the transistor Q28 and the collector of the transistor Q12. The resistor R12 is connected between the base and collector of the transistor Q28. Through the collector of the transistor Q12 there is supplied the output signal OUT of the VCO is supplied.
The variable-reactance circuit 52 comprises a capacitor C11, an amplifying section 21, differential sections 22 and 23, and a signal-supplying section 24. The amplifying section 21 comprises npn bipolar transistors Q21 to Q23, constant-current sources I21 to I24, resistors R1 to R4, and a diode D3. The first differential section 22 comprises npn bipolar transistors Q24 and Q25 and a variable-current source Iv1. The second differential section 23 comprises npn bipolar transistors Q26 and Q27 and a variable-current source Iv2. The signal-supplying section 24 comprises a resistor R5 and a capacitor C12.
The components of the variable-reactance circuit 52 are connected as will be indicated below.
The resistor R1 is connected between the emitter of the transistor Q21 and the power-supply terminal 10a. The constant-current source I21 is connected between the collector of the transistor Q21 and the power-supply terminal 10b. The base and collector of the transistor Q21 are connected to each other. The resistor R2 is connected between the emitter of the transistor Q22 and the power-supply terminal 10a. The constant-current I22 is connected between the collector of the transistor Q22 and the power-supply terminal 10b. The bases of the transistors Q21 and Q22 are connected to each other.
The constant-current source I23 is connected between the collector of the transistor Q23 and the power-supply terminal 10b. The base of the transistor Q23 is connected to the collector of the transistor Q22. The emitter of the transistor Q23 is connected to the emitter of the transistor Q21. The resistor R4 is connected to the power-supply terminal 10a, and the constant-current source I24 to the power-supply terminal 10b. The diode D3 is connected between the constant-current source I24 and the resistor R4. The diode D3 is composed of, for example, an npn bipolar transistor whose collector and base are connected together. The resistor R3 is connected between the collector of the transistor Q23 and the node C of the constant-current source I24 and the diode D3.
The variable-current source Iv1 is connected between the emitter node of the transistors Q24 and Q25 and the power-supply terminal 10a. The output current of the variable-current source Iv1 is controlled by a control signal supplied to a control terminal 11a. The variable-current source Iv2 is connected between the emitter node of the transistors Q26 and Q27 and the power-supply terminal 10a. The output current of the variable-current source Iv2 is controlled by a control signal supplied to a control terminal 11b.
The bases of the transistors Q24 and Q26 are connected to the collector (i.e., node B) of the transistor Q23. The bases of the transistors Q25 and Q27 are connected to the collector (i.e., node A) of the transistor Q21. The collectors of the transistors Q24 and Q27 are connected to the power-supply terminal 10b. The collectors of the transistors Q25 and Q26 are connected to the emitter of the transistor Q21 by the capacitor C11. The collectors of the transistors Q25 and Q26 are connected to the collector of the transistor Q12 incorporated in the oscillator 51. (The collector of the transistor Q12 serves as the output node 13 of the VCO.)
The reactance as viewed from the output node 13 of the VCO varies with the value of the control signals applied to the control terminals 11a and 11b, i.e., the values of the currents supplied from the variable-current sources Iv1 and Iv2. Hence, the control signals applied to the control terminals 11a and 11b change the frequency of the signal OUT from the VCO.
Assume that I1=I2=I3=I4=I and that R1:R2:R4=1:2:2. Here, I1, I2, I3 and I4 are the output currents of the constant-current sources I1, I2, I3 and I4, respectively, and R1, R2, R3 and R4 are the resistances of the resistors R1, R2, R3 and R4, respectively. Then, the reactance of the output node 13 of the VCO can change on the basis of the control signals supplied to the control terminals 11a and 11b.
The variable-reactance circuit 52 can operate, provided that the power-supply voltage is equal to or higher than the voltage (about 0.7 V) between the base of the transistor Q24 and the emitter of the transistor Q26. In other words, the circuit 52 operates if a potential of 0.7 or more is applied to the power-supply terminal 10b while the ground potential GND is applied to the power-supply terminal 10a. Thus, the variable-reactance circuit 52 can reliably operate at a power-supply voltage of about 1 V.
FIG. 4 shows a VCO incorporating a variable-reactance circuit according to the third embodiment of the invention. As seen from FIG. 4, this VCO has an oscillator 51 and a variable-reactance circuit 52, too.
The oscillator 51 comprises npn bipolar transistors Q11 and Q12, a constant-current source I11, a reference-voltage source V, and a resonator 12. The components of the oscillator 51 are connected as will be indicated below.
The constant-current source I11 is connected between the emitter node of the transistors Q11 and Q12 and a power-supply terminal 10a. A low potential, for example the ground potential GND, is applied to the power-supply terminal 10a. The collector of the transistor Q11 is connected to a power-supply terminal 10b, to which a high potential VCC is applied. The base of the transistor Q11 is connected to the collector of the transistor Q12. The reference-voltage source V is connected between the base of the transistor Q12 and the power-supply terminal 10a. The resonator 12 is connected between the collector of the transistor Q12 and the power-supply terminal 10b. Through the collector of the transistor Q12 there is supplied the output signal OUT of the VCO is supplied.
The variable-reactance circuit 52 comprises a capacitor C11, an amplifying section 21, and differential sections 22 and 23. The amplifying section 21 comprises npn bipolar transistors Q21 to Q23, constant-current sources I21 to I23, resistors R1 to R3, and a diode D3. The first differential section 22 comprises npn bipolar transistors Q24 and Q25 and a variable-current source Iv1. The second differential section 23 comprises npn bipolar transistors Q26 and Q27 and a variable-current source Iv2.
The components of the variable-reactance circuit 52 are connected as will be described below.
The resistor R1 is connected between the emitter of the transistor Q21 and the power-supply terminal 10a. The constant-current source I21 is connected between the collector of the transistor Q21 and the power-supply terminal 10b. The base and collector of the transistor Q21 are connected to each other. The resistor R2 is connected between the emitter of the transistor Q22 and the power-supply terminal 10a. The constant-current I22 is connected between the collector of the transistor Q22 and the power-supply terminal 10b. The bases of the transistors Q21 and Q22 are connected to each other.
The constant-current source I23 is connected between the collector of the transistor Q23 and the power-supply terminal 10b. The base of the transistor Q23 is connected to the collector of the transistor Q22. The emitter of the transistor Q23 is connected to the emitter of the transistor Q21. The diode D3 and the resistor R3 are connected in series between the constant-current source I23 and the power-supply terminal 10a. The diode D3 is composed of, for example, an npn bipolar transistor whose collector and base are connected together.
The output currents of the constant-current sources I21, I22 and I23 have the relationship of: I21:I22:I23=1:1:2. The resistances of the resistors R1, R2 and R3 have the relationship of: R1:R2:R3=1:2:2. Here, I21, I22 and I23 are the output currents of the sources I21, I22 and I23, respectively, and R1, R2 and R3 are the resistances of the resistors R1, R2 and R3, respectively.
The variable-current source Iv1 is connected between the emitter node of the transistors Q24 and Q25 and the power-supply terminal 10a. The output current of the variable-current source Iv1 is controlled by a control signal supplied to a control terminal 11a. The variable-current source Iv2 is connected between the emitter node of the transistors Q26 and Q27 and the power-supply terminal 10a. The output current of the variable-current source Iv2 is controlled by a control signal supplied to a control terminal 11b.
The bases of the transistors Q24 and Q26 are connected to the collector (i.e., node B) of the transistor Q23. The bases of the transistors Q25 and Q27 are connected to the collector (i.e., node A) of the transistor Q21. The collectors of the transistors Q24 and Q27 are connected to the power-supply terminal 10b. The collectors of the transistors Q25 and Q26 are connected to the emitter of the transistor Q21 by the capacitor C11. The collectors of the transistors Q25 and Q26 are connected to the collector of the transistor Q12 incorporated in the oscillator 51. (The collector of the transistor Q12 serves as the output node 13 of the VCO.)
The reactance as viewed from the output node 13 of the VCO varies with the value of the control signals applied to the control terminals 11a and 11b, i.e., the values of the currents supplied from the variable-current sources Iv1 and Iv2. The control signals applied to the control terminals 11a and 11b therefore change the frequency of the signal OUT from the VCO.
In the variable-reactance circuit of FIG. 4, a current {=I21+(I23/2)} flows through the resistor R1. Therefore, the voltage drop across the resistor R1 is {I21+(I23/2)}×R1. The output current of the constant-current source I23 is divided into two parts. The first part of the current flows to the transistor Q23, while the second part of the current flows to the resistor R3 and the diode D3. More precisely, a current of I23/2 flows to the resistor R3. Thus, the voltage drop at the resistor R3 is (I23/2)×R3. This voltage drop determines the bias voltage which is applied to the collector of the transistor Q23.
Assuming that the current amplification factors of the transistors Q21 to Q27 are infinitely large, the potentials at the nodes A and B are equal.
The third embodiment (FIG. 4) has neither the resistor R4 nor the constant-current source I24. Made of less components, the third embodiment serves to reduce the size of a semiconductor chip in which it is formed, and occupies but a relatively small area in the element region of a semiconductor chip.
FIG. 5 illustrates a VCO incorporating a variable-reactance circuit according to the fourth embodiment of the present invention. As shown in FIG. 5, the VCO has an oscillator 51 and a variable-reactance circuit 52, too.
The oscillator 51 comprises npn bipolar transistors Q11 and Q12, a constant-current source I11, a reference-voltage source V, and a resonator 12. The components of the oscillator 51 are connected as will be indicated below.
The constant-current source I11 is connected between the emitter node of the transistors Q11 and Q12 and a power-supply terminal 10a. A low potential, for example the ground potential GND, is applied to the power-supply terminal 10a. The collector of the transistor Q11 is connected to a power-supply terminal 10b, to which a high potential VCC is applied. The base of the transistor Q11 is connected to the collector of the transistor Q12. The reference-voltage source V is connected between the base of the transistor Q12 and the power-supply terminal 10a. The resonator 12 is connected between the collector of the transistor Q12 and the power-supply terminal 10b. Through the collector of the transistor Q12 there is supplied the output signal OUT of the VCO is supplied.
The variable-reactance circuit 52 comprises a capacitor C11, an amplifying section 21, and differential sections 22 and 23. The amplifying section 21 comprises npn bipolar transistors Q21 to Q23, constant-current sources I21 and I22, and resistors R1 and R2. The first differential section 22 comprises npn bipolar transistors Q24 and Q25 and a variable-current source Iv1. The second differential section 23 comprises npn bipolar transistors Q26 and Q27 and a variable-current source Iv2.
The components of the variable-reactance circuit 52 are connected as will be described below.
The resistor R1 is connected between the emitter of the transistor Q21 and the power-supply terminal 10a. The constant-current source I21 is connected between the collector of the transistor Q21 and the power-supply terminal 10b. The base and collector of the transistor Q21 are connected to each other. The resistor R2 is connected between the emitter of the transistor Q22 and the power-supply terminal 10a. The constant-current I22 is connected between the collector of the transistor Q22 and the power-supply terminal 10b. The bases of the transistors Q21 and Q22 are connected to each other.
The collector and base of the transistor Q23 are connected to the power-supply terminal 10b and the collector of the transistor Q22, respectively. The emitter of the transistor Q23 is connected to the emitter of the transistor Q21.
The variable-current source Iv1 is connected between the emitter node of the transistors Q24 and Q25 and the power-supply terminal 10a. The output current of the variable-current source Iv1 is controlled by a control signal supplied to a control terminal 11a. The variable-current source Iv2 is connected between the emitter node of the transistors Q26 and Q27 and the power-supply terminal 10a. The output current of the variable-current source Iv2 is controlled by a control signal supplied to a control terminal 11b.
The bases of the transistors Q24 and Q26 are connected to the collector of the transistor Q23. The bases of the transistors Q25 and Q27 are connected to the collector of the transistor Q21. The collectors of the transistors Q24 and Q27 are connected to the power-supply terminal 10b. The collectors of the transistors Q25 and Q26 are connected to the emitter of the transistor Q21 by the capacitor C11. The collectors of the transistors Q25 and Q26 are connected to the collector of the transistor Q12 incorporated in the oscillator 51. (The collector of the transistor Q12 serves as the output node 13 of the VCO.)
The reactance as viewed from the output node 13 of the VCO varies with the value of the control signals applied to the control terminals 11a and 11b, i.e., the values of the currents supplied from the variable-current sources Iv1 and Iv2. The control signals applied to the control terminals 11a and 11b therefore change the frequency of the signal OUT from the VCO.
Therefore, the reactance of the output node of the VCO can change in accordance with the control signals supplied to the control terminals 11a and 11b, and the power-supply voltage can be reduced to 1 V or less.
The fourth embodiment (FIG. 5) differs from the first embodiment (FIG. 2) in that there are provided no components which correspond to the resistors R3 and R4, the diode D3 and the constant-current sources I23 and I24. Made of less components, the fourth embodiment serves to reduce the size of a semiconductor chip in which it is formed, and occupies but a relatively small area in the element region of a semiconductor chip.
FIG. 6 shows a VCO which incorporates a variable-reactance circuit according to the fifth embodiment of the invention. As seen from FIG. 6, the VCO has an oscillator 51 and a variable-reactance circuit 52.
The oscillator 51 comprises npn bipolar transistors Q11 and Q12, a constant-current source I11, a reference-voltage source V, and a resonator 12. The components of the oscillator 51 are connected as will be described below.
The constant-current source I11 is connected between the emitter node of the transistors Q11 and Q12 and a power-supply terminal 10a. A low potential, for example the ground potential GND, is applied to the power-supply terminal 10a. The collector of the transistor Q11 is connected to a power-supply terminal 10b, to which a high potential VCC is applied. The base of the transistor Q11 is connected to the collector of the transistor Q12. The reference-voltage source V is connected between the base of the transistor Q12 and the power-supply terminal 10a. The resonator 12 is connected between the collector of the transistor Q12 and the power-supply terminal 10b. Through the collector of the transistor Q12 there is supplied the output signal OUT of the VCO is supplied.
The variable-reactance circuit 52 comprises a capacitor C11, an amplifying section 21, and differential section 22. The amplifying section 21 comprises npn bipolar transistors Q21 to Q23, constant-current sources I21 to I24, resistors R1 to R4, and a diode D3. The differential section 22 comprises npn bipolar transistors Q24 and Q25 and a variable-current source Iv1.
The components of the variable-reactance circuit 52 are connected as will be indicated below.
The resistor R1 is connected between the emitter of the transistor Q21 and the power-supply terminal 10a. The constant-current source I21 is connected between the collector of the transistor Q21 and the power-supply terminal 10b. The base and collector of the transistor Q21 are connected to each other. The resistor R2 is connected between the emitter of the transistor Q22 and the power-supply terminal 10a. The constant-current I22 is connected between the collector of the transistor Q22 and the power-supply terminal 10b. The bases of the transistors Q21 and Q22 are connected to each other.
The constant-current source I23 is connected between the collector of the transistor Q23 and the power-supply terminal 10b. The base of the transistor Q23 is connected to the collector of the transistor Q22. The emitter of the transistor Q23 is connected to the emitter of the transistor Q21. The resistor R4 is connected to the power-supply terminal 10a, and the constant-current source I24 to the power-supply terminal 10b. The diode D3 is connected between the constant-current source I24 and the resistor R4. The diode D3 is composed of, for example, an npn bipolar transistor whose collector and base are connected together. The resistor R3 is connected between the collector of the transistor Q23 and the node C of the constant-current source I24 and the diode D3.
The variable-current source Iv1 is connected between the emitter node of the transistors Q24 and Q25 and the power-supply terminal 10a. The output current of the variable-current source Iv1 is controlled by a control signal supplied to a control terminal 11a.
The bases of the transistor Q24 is connected to the collector (i.e., node B) of the transistor Q23. The bases of the transistor Q25 is connected to the collector (i.e., node A) of the transistor Q21. The collectors of the transistor Q24 is connected to the power-supply terminal 10b. The collectors of the transistor Q25 is connected to the emitter of the transistor Q21 by the capacitor C11. The collectors of the transistor Q25 is connected to the collector of the transistor Q12 incorporated in the oscillator 51. (The collector of the transistor Q12 serves as the output node 13 of the VCO.)
The reactance as viewed from the output node 13 of the VCO varies with the value of the control signals applied to the control terminals 11a and 11b, i.e., the values of the currents supplied from the variable-current source Iv1. Hence, the control signals applied to the control terminal 11a change the frequency of the signal OUT from the VCO.
Additional advantages and modifications will readily occur to those skilled in the art. Therefore, the invention in its broader aspects is not limited to the specific details, and representative devices shown and described herein. Accordingly, various modifications may be made without departing from the spirit or scope of the general inventive concept as defined by the appended claims and their equivalents. | A variable-reactance circuit comprising an amplifying section, a first differential section and a second differential section. The amplifying section has first to third bipolar transistors. These transistors are driven by three constant-current sources, respectively. The first differential section receives an output signal of the amplifying section. The first differential section has fourth and fifth bipolar transistors, which are driven by a first variable-current source. The second differential section receives the output signal of the amplifying section. The second differential section has sixth and seventh bipolar transistors, which are driven by a second variable-current source. The output currents of the first and second variable-current sources are controlled by two control signals, respectively. | 7 |
This application is the U.S. National Phase of PCT International Application PCT/EP2012/069675, filed Oct. 5, 2012, claiming priority of European Patent Application No. 11184248.0, filed Oct. 7, 2011, and the benefit under 35 U.S.C. 119(e) of U.S. Provisional Application No. 61/545,532 filed Oct. 10, 2011, the contents of which are incorporated herein by reference in their entirety.
FIELD OF INVENTION
The present invention relates to a propylene polymer composition having improved flexural modulus, impact strength and excellent optical properties.
BACKGROUND OF THE INVENTION
As is known, the isotactic polypropylene is endowed with an exceptional combination of excellent properties which render it suitable for a very great number of uses.
In order to improve the properties of the isotactic polypropylene the crystallinity of the propylene homopolymer is decreased by copolymerization of the propylene with small quantities of ethylene and/or α-olefins such as 1-butene, 1-pentene and 1-hexene. In this manner one obtains the so called random crystalline propylene copolymers which, when compared to the homopolymer, are essentially characterized by better flexibility and transparency.
Propylene random copolymers, however, although they have good transparency, do not offer, especially at low temperatures, sufficiently better impact resistance than the homopolymer which can be satisfactory used for the applications listed above.
It has been known for a long time that the impact resistance of polypropylene can be improved by adding an adequate quantity of elastomeric propylene-ethylene copolymer to the homopolymers by mechanical blending or sequential polymerization. However, this improvement is obtained at the expenses of the transparency of the material.
To avoid this inconvenient, U.S. Pat. No. 4,634,740 suggests the blending of the polypropylene, in the molten state, with propylene-ethylene copolymers obtained with specific catalysts, and having an ethylene content ranging from 70 to 85% by weight. However, said compositions present transparency values (Haze) substantially comparable to those of the propylene homopolymer. Said patent, therefore, does not teach how to obtain compositions having good transparency.
EP-A-0557953, describes polyolefin compositions where one obtains a good balance of transparency, stiffness, and impact resistance even at low temperatures, by modifying a crystalline random copolymer of propylene with the proper quantities of a mechanical mixture comprising an elastomeric copolymer and one or more polymers chosen from LLDPE, LDPE and HDPE.
WO 01/92406 describes a propylene polymer composition comprising (percent by weight):
A) from 70 to 90%, of a random copolymer of propylene with ethylene, containing from 1 to 6%, of ethylene, having a content of fraction insoluble in xylene at room temperature of not less than 93; B) from 10% to 30%, of a copolymer of propylene with ethylene, containing from 8 to 18%, of ethylene;
wherein the ratio (B)/C 2 B of the percent by weight of (B), with respect to the total weight of (A) and (B), to the percent by weight of ethylene in (B), with respect to the total weight of (B), represented in the above formula by C 2 B , is 2.5 or lower. The MFR L ranges from 0.5 to 50 g/10 min. This composition shows a good transparency but quite low values of flexural modulus.
SUMMARY OF THE INVENTION
The applicant found a propylene polymer composition having a particular balance among the various parameter so that to obtain improved values of flexural modulus, good values of haze and good resistance to impact.
Thus one object of the present invention is a propylene polymer composition comprising:
A) from 70 wt % to 95 wt %, preferably from 74 wt % to 86 wt %, more preferably from of 77 wt % to 84 wt % of a random copolymer of propylene with ethylene, containing from 1.5 wt % to 4.5 wt %, preferably from 2.0 wt % to 3.5 wt %, of ethylene derived units, having a content of fraction insoluble in xylene at 25° C. of not less than 93 wt %, preferably not less than 94 wt %; B) from 5 wt % to 35 wt %, preferably from 14 wt % to 26 wt %, more preferably from 16 wt % to 23 wt % of a copolymer of propylene with ethylene, containing from 7.0 wt % to 17.0 wt %, preferably from 8.0 wt % to 16 wt %, of ethylene derived units;
the sum A+B being 100;
wherein the melt flow rate, MFR. (ISO 1133 (230° C., 2.16 kg).) ranges from 30 g/10 min and 130 g/10 min; preferably from 40 g/10 min to 120 g/10 min; more preferably from 55 g/10 min to 110 g/10 min; even more preferably from 70 g/10 min to 100 g/10 min and wherein the relation (I) is fulfilled:
10< XS*C 2 A −MFR/ C 2 B< 30 (I)
wherein XS is the wt % of xylene soluble content at 25° C. of the total composition;
C2A is the wt % of ethylene derived units content of component A; MFR is the melt flow rate of the total composition; C2B is the wt % of ethylene derived units content of component B.
DETAILED DESCRIPTION OF THE INVENTION
Preferably relation (I) is
15< XS*C 2 A −MFR/ C 2 B< 28; (Ia)
More preferably
20< XS*C 2 A −MFR/ C 2 B< 25; (Ib).
Higher value of the relation correspond to unsatisfactory values of flexural modulus, while lower values of the relation correspond to unsatisfactory value of impact properties.
Preferably the ratio (B)/C2B wherein (B) is the amount wt % of B with respect to the total weight of (A) and (B) and C2B represents the wt % of ethylene derived units in B ranges from 2.5 to 1.5, preferably it is comprised between 1.8 and 2.4; more preferably between 2.1 and 2.3.
The term “copolymer” includes polymers containing only propylene and ethylene.
The present invention is preferably endowed with one or more of the following features:
Polydispersity Index (PI): 5 or less, more preferably 4 or less; Intrinsic Viscosity [η] of the fraction (of the overall composition) insoluble in xylene at room temperature: from 1.5 to 3, more preferably from 2 to 2.5 dl/g; Intrinsic Viscosity [η] of the fraction (of the overall composition) soluble in xylene at room temperature: from 1 to 4.5, more preferably from 1.5 to 4 dl/g.
The compositions of the present invention present at least one melt peak, determined by way of DSC (Differential Scanning Calorimetry), at a temperature higher than 140; preferably higher than 145° C.
Moreover, the compositions of the present invention preferably have one or more of the following features:
a Flexural Modulus higher than 800 MPa preferably higher than 880 and more preferably higher than 900 MPa, preferably the Flexural Modulus is lower than 1800 MPa, more preferably it is lower than 1500 MPa; Haze less than 15% preferably less than 11% on 1 mm plaques; fraction soluble in xylene at room temperature: less than 20%, more preferably less than 15%.
The compositions of the present invention can be prepared by sequential polymerization in at least two polymerization steps. Such polymerization is carried out in the presence of stereospecific Ziegler-Natta catalysts. An essential component of said catalysts is a solid catalyst component comprising a titanium compound having at least one titanium-halogen bond, and an electron-donor compound, both supported on a magnesium halide in active form. Another essential component (co-catalyst) is an organoaluminum compound, such as an aluminum alkyl compound.
An external donor is optionally added.
The catalysts generally used in the process of the invention are capable of producing polypropylene with an Isotacticity Index greater than 90%, preferably greater than 95%.
Moreover, said catalysts must have a sensitivity to molecular weight regulators (particularly hydrogen) high enough to produce polypropylene having MFR values from less than 1 g/10 min. to 100 g/10 min. or more.
Catalysts having the above mentioned characteristics are well known in the patent literature; particularly advantageous are the catalysts described in U.S. Pat. No. 4,399,054 and European patent 45977. Other examples can be found in U.S. Pat. No. 4,472,524.
The solid catalyst components used in said catalysts comprise, as electron-donors (internal donors), compounds selected from the group consisting of ethers, ketones, lactones, compounds containing N, P and/or S atoms, and esters of mono- and dicarboxylic acids.
Particularly suitable electron-donor compounds are 1,3-diethers of formula:
wherein R I and R II are the same or different and are C 1 -C 18 alkyl, C 3 -C 18 cycloalkyl or C 7 -C 18 aryl radicals; R III and R IV are the same or different and are C 1 -C 4 alkyl radicals; or are the 1,3-diethers in which the carbon atom in position 2 belongs to a cyclic or polycyclic structure made up of 5, 6, or 7 carbon atoms, or of 5-n or 6-n′ carbon atoms, and respectively n nitrogen atoms and n′ heteroatoms selected from the group consisting of N, O, S and Si, where n is 1 or 2 and n′ is 1, 2, or 3, said structure containing two or three unsaturations (cyclopolyenic structure), and optionally being condensed with other cyclic structures, or substituted with one or more substituents selected from the group consisting of linear or branched alkyl radicals; cycloalkyl, aryl, aralkyl, alkaryl radicals and halogens, or being condensed with other cyclic structures and substituted with one or more of the above mentioned substituents that can also be bonded to the condensed cyclic structures; one or more of the above mentioned alkyl, cycloalkyl, aryl, aralkyl, or alkaryl radicals and the condensed cyclic structures optionally containing one or more heteroatoms as substitutes for carbon or hydrogen atoms, or both.
Ethers of this type are described in published European patent applications 361493 and 728769.
Representative examples of said dieters are 2-methyl-2-isopropyl-1,3-dimethoxypropane, 2,2-diisobutyl-1,3-dimethoxypropane, 2-isopropyl-2-cyclopentyl-1,3-dimethoxypropane, 2-isopropyl-2-isoamyl-1,3-dimethoxypropane, 9,9-bis(methoxymethyl) fluorene.
By using the said dieters, the previously said preferred P.I. values are obtained directly in polymerization.
Other suitable electron-donor compounds are phthalic acid esters, such as diisobutyl, dioctyl, diphenyl and benzylbutyl phthalate.
The preparation of the above mentioned catalyst components is carried out according to various methods.
For example, a MgCl 2 .nROH adduct (in particular in the form of spheroidal particles) wherein n is generally from 1 to 3 and ROH is ethanol, butanol or isobutanol, is reacted with an excess of TiCl 4 containing the electron-donor compound. The reaction temperature is generally from 80 to 120° C. The solid is then isolated and reacted once more with TiCl 4 , in the presence or absence of the electron-donor compound, after which it is separated and washed with aliquots of a hydrocarbon until all chlorine ions have disappeared.
In the solid catalyst component the titanium compound, expressed as Ti, is generally present in an amount from 0.5 to 10% by weight. The quantity of electron-donor compound which remains fixed on the solid catalyst component generally is 5 to 20% by moles with respect to the magnesium dihalide.
The titanium compounds which can be used for the preparation of the solid catalyst component are the halides and the halogen alcoholates of titanium. Titanium tetrachloride is the preferred compound.
The reactions described above result in the formation of a magnesium halide in active form. Other reactions are known in the literature, which cause the formation of magnesium halide in active form starting from magnesium compounds other than halides, such as magnesium carboxylates.
The active form of magnesium halide in the solid catalyst component can be recognized by the fact that in the X-ray spectrum of the catalyst component the maximum intensity reflection appearing in the spectrum of the nonactivated magnesium halide (having a surface area smaller than 3 m 2 /g) is no longer present, but in its place there is a halo with the maximum intensity shifted with respect to the position of the maximum intensity reflection of the nonactivated magnesium dihalide, or by the fact that the maximum intensity reflection shows a width at half-peak at least 30% greater than the one of the maximum intensity reflection which appears in the spectrum of the nonactivated magnesium halide. The most active forms are those where the above mentioned halo appears in the X-ray spectrum of the solid catalyst component.
Among magnesium halides, the magnesium chloride is preferred. In the case of the most active forms of magnesium chloride, the X-ray spectrum of the solid catalyst component shows a halo instead of the reflection which in the spectrum of the nonactivated chloride appears at 2.56 Å.
The Al-alkyl compounds used as co-catalysts comprise the Al-trialkyls, such as Al-triethyl, Al-triisobutyl, Al-tri-n-butyl, and linear or cyclic Al-alkyl compounds containing two or more Al atoms bonded to each other by way of O or N atoms, or SO 4 or SO 3 groups.
The Al-alkyl compound is generally used in such a quantity that the Al/Ti ratio be from 1 to 1000.
The electron-donor compounds that can be used as external donors include aromatic acid esters such as alkyl benzoates, and in particular silicon compounds containing at least one Si—OR bond, where R is a hydrocarbon radical.
Examples of silicon compounds are (tert-butyl) 2 Si (OCH 3 ) 2 , (cyclohexyl)(methyl) Si (OCH 3 ) 2 , (phenyl) 2 Si (OCH 3 ) 2 and (cyclopentyl) 2 Si (OCH 3 ) 2 . 1,3-diethers having the formulae described above can also be used advantageously. If the internal donor is one of these dieters, the external donors can be omitted.
As previously said, the polymerization process can be carried out in at least two sequential steps, wherein components A) and B) are prepared in separate subsequent steps, operating in each step, except the first step, in the presence of the polymer formed and the catalyst used in the preceding step. The catalyst is generally added only in the first step, however its activity is such that it is still active for all the subsequent step(s).
Component A) is preferably prepared before component B).
The regulation of the molecular weight is carried out by using known regulators, hydrogen in particular.
By properly dosing the concentration of the molecular weight regulator in the relevant steps, the previously described MFR and [η] values are obtained.
The whole polymerization process, which can be continuous or batch, is carried out following known techniques and operating in liquid phase, in the presence or not of inert diluent, or in gas phase, or by mixed liquid-gas techniques. It is preferable to carry out the propylene copolymerization step(s) for preparation of component A) in liquid propylene as diluent, and the other polymerization step(s) in gas phase. Generally there is no need for intermediate steps except for the degassing of unreacted monomers.
Reaction time, pressure and temperature relative to the two steps are not critical, however it is best if the temperature is from 20 to 100° C. The pressure can be atmospheric or higher.
The catalysts can be pre-contacted with small amounts of olefins (prepolymerization).
The compositions of the present invention can also be obtained by preparing separately the said components A) and B) by operating with the same catalysts and substantially under the same polymerization conditions as previously explained (except that a wholly sequential polymerization process will not be carried out, but the said components and fractions will be prepared in separate polymerization steps) and then mechanically blending said components and fractions in the molten or softened state. Conventional mixing apparatuses, like screw extruders, in particular twin screw extruders, can be used.
The compositions of the present invention can also contain additives commonly employed in the art, such as antioxidants, light stabilizers, heat stabilizers, nucleating agents, colorants and fillers.
In particular, the addition of nucleating agents brings about a considerable improvement in important physical-mechanical properties, such as Flexural Modulus, Heat Distortion Temperature (HDT), tensile strength at yield and transparency.
Typical examples of nucleating agents are the p-tert.-butyl benzoate and the 1,3- and 2,4-dibenzylidenesorbitols.
The nucleating agents are preferably added to the compositions of the present invention in quantities ranging from 0.05 to 2% by weight, more preferably from 0.1 to 1% by weight with respect to the total weight.
The addition of inorganic fillers, such as talc, calcium carbonate and mineral fibers, also brings about an improvement to some mechanical properties, such as Flexural Modulus and HDT. Talc can also have a nucleating effect.
The compositions of the present invention are particularly suited for the production of injection molding articles in particular containers, especially food containers. Due to the impact properties at low temperature the composition of the present invention is especially fit for the preparation of containers for frozen food such as ice cream, eggs, yoghurt, fish and frozen fish.
The particulars are given in the following examples, which are given to illustrate, without limiting, the present invention.
EXAMPLES
Methods of analysis used.
The data shown in the following Table are obtained by using the following test methods.
Melt Flow Rate
Determined according to ISO 1133 (230° C., 2.16 kg).
Ethylene Content of the Polymers (C2 Content)
Ethylene content has been determined by IR spectroscopy.
The spectrum of a pressed film of the polymer is recorded in absorbance vs. wavenumbers (cm −1 ). The following measurements are used to calculate C2 content:
a) Area (A t ) of the combination absorption bands between 4482 and 3950 cm −1 which is used for spectrometric normalization of film thickness. b) Area (A C2 ) of the absorption band due to methylenic sequences (CH 2 rocking vibration) after a proper digital subtraction of an isotactic polypropylene (IPP) reference spectrum. The range 660 to 790 cm −1 .
Molar Ratios of the Feed Gases
Determined by gas-chromatography.
Samples for the Mechanical Analysis
Samples have been obtained according to ISO 294-2
Flexural Modulus
Determined according to ISO 178.
Haze (on 1 mm Plaque)
According to the method used, 5×5 cm specimens are cut molded plaques of 1 mm thick and the haze value is measured using a Gardner photometric unit connected to a Hazemeter type UX-10 or an equivalent instrument having G.E. 1209 light source with filter “C”. Reference samples of known haze are used for calibrating the instrument. The plaques to be tested are produced according to the following method.
75×75×1 mm plaques are molded with a GBF Plastiniector G235190 Injection Molding Machine, 90 tons under the following processing conditions:
Screw rotation speed: 120 rpm Back pressure: 10 bar Melt temperature: 260° C. Injection time: 5 sec Switch to hold pressure: 50 bar First stage hold pressure: 30 bar Second stage pressure: 20 bar Hold pressure profile: First stage 5 sec Second stage 10 sec Cooling time: 20 sec Mold water temperature: 40° C.
Melting Temperature, Melting Enthalpy and Crystallization Temperature
Determined by differential scanning calorimetry (DSC). A sample weighting 61 mg, is heated to 220±1° C. at a rate of 20° C./min and kept at 220±1° C. for 2 minutes in nitrogen stream and it is thereafter cooled at a rate of 20° C./min to 40±2° C., thereby kept at this temperature for 2 min to crystallise the sample. Then, the sample is again fused at a temperature rise rate of 20° C./min up to 220° C.±1. The melting scan is recorded, a thermogram is obtained, and, from this, melting temperatures (Tm) and crystallization temperature (Tc) are read.
Xylene Soluble and Insoluble Fractions
2.5 g of polymer and 250 cm 3 of xylene are introduced in a glass flask equipped with a refrigerator and a magnetical stirrer. The temperature is raised in 30 minutes up to the boiling point of the solvent. The so obtained clear solution is then kept under reflux and stirring for further 30 minutes. The closed flask is then kept for 30 minutes in a ermostatic water bath at 25° C. for 30 minutes. The so formed solid is filtered on quick filtering paper. 100 cm 3 of the filtered liquid is poured in a previously weighed aluminum container which is heated on a heating plate under nitrogen flow, to remove the solvent by evaporation. The container is then kept in an oven at 80° C. under vacuum until constant weight is obtained. The weight percentage of polymer soluble in xylene at room temperature is then calculated. The percent by weight of polymer insoluble in xylene at room temperature is considered the Isotacticity Index of the polymer. This value corresponds substantially to the Isotacticity Index determined by extraction with boiling n-heptane, which by definition constitutes the Isotacticity Index of polypropylene.
Itrinsic Viscosity (I.V.)
Determined in tetrahydronaphthalene at 135° C.
IZOD Impact Strength
Determined according to ISO 180/1A
Solid Catalyst Component
The solid catalyst component used in polymerization is a highly stereospecific Ziegler-Natta catalyst component supported on magnesium chloride, prepared as follows.
Into a 500 mL four-necked round flask, purged with nitrogen, 250 mL of TiCl 4 were introduced at 0° C. While stirring, 10.0 g of microspheroidal MgCl 2 *2.8C 2 H 5 OH (prepared according to the method described in ex.2 of U.S. Pat. No. 4,399,054 but operating at 3000 rpm instead of 10000 rpm) and 7.4 mmol of 9,9-bis(methoxymethyl)fluorene were added. The temperature was raised to 100° C. and maintained for 120 min. Then, the stirring was discontinued, the solid product was allowed to settle and the supernatant liquid was siphoned off. Then 250 mL of fresh TiCl 4 were added. The mixture was reacted at 120° C. for 60 min and, then, the supernatant liquid was siphoned off. The solid was washed six times with anhydrous hexane (6×100 mL) at 60° C. Finally, the solid was dried under vacuum and analyzed. The resulting solid catalyst component contained: Ti=3.5% by weight, 9,9-bis(methoxymethyl)fluorene=18.1% by weight.
Catalyst System and Prepolymerization Treatment
Before introducing it into the polymerization reactors, the solid catalyst component described above is contacted at 15° C. for 30 minutes with aluminum triethyl (TEAL) in such quantity that the TEAL/Ti molar ratio be equal to 300.
The catalyst system is then subjected to prepolymerization by maintaining it in suspension in liquid at the conditions reported in table 1.
Polymerization
The polymerization runs were conducted in continuous in a series of two reactors equipped with devices to transfer the product from one reactor to the one immediately next to it. The first reactor is a liquid phase reactor, and the second is a fluid bed gas phase reactor.
Unless otherwise specified, temperature and pressure were maintained constant throughout the course of the reaction. Hydrogen was used as molecular weight regulator.
The gas phase (propylene, ethylene and hydrogen) is continuously analyzed via gas-chromatography.
At the end of the run the powder was discharged, stabilized following known techniques, dried in an oven at 60° C. under a nitrogen flow and pelletized. The polymerization parameters are reported in table 1.
TABLE 1
Ex
1
2
3
Precontact
Temperature ° C.
12
12
12
Residence time (min)
23
22
21
Teal/donor ratio
4
4
3
Prepolymerization
Temperature ° C.
20
20
20
Residence time (min)
9
9
9
Loop 1 st reactor in liquid phase -
component A)
Temperature, ° C.
70
70
68
Pressure, bar
40
40
40
Residence time, min
57
56
53
H 2 feed mol ppm
7000
6800
8900
C2 feed (kg/h)
3
2.2
2.1
C2− loop wt %
3
2.6
2.5
Xylene Solubles %
5.1
3.8
4.2
Split, wt %
80
80
80
Gas-Phase reactor - component B)
Temperature, ° C.
75
75
75
Pressure, bar
20
20
20
Residence time, min
23
40
34
C 2 − /C 2 − + C 3 − , %
0.071
0.075
0.076
H 2 /C 3 − , %
0.2
0.216
0.27
Split, wt %
20
20
20
% C2− in copolymer
9.5
10
10.5
C2 − = ethylene;
C3 − = propylene;
H2 = hydrogen
To the polymers of examples 1-3 the additives reported on table 2 were added. The analysis of the resulting polymers is reported in table 3.
TABLE 2
Additive
Amount (ppm)
Irganox 1010
500
Irgafos 168
1000
Ca Stearate
500
GMS 90
1750
Millad 3998
1800
Comparative Example 1
Comparative example 4 is example 2 of WO 01/92406.
TABLE 3
Example
Comparative
1
2
3
ex 4
Component A)
MFR
g/10′
46
45
75
2.2
C2
%
3.0
2.6
2.1
2.8
Xylene Soluble (XS)
%
5.1
3.8
4.2
5.3
Component B)
% C2 bipolymer by calc.
%
9.5
10
10.5
13.5
Split (amount of
%
20
20
20
19
component B).
Total composition
MFR
g/10′
45
48
86
1.7
C2
%
4.6
3.7
4.4
4.8
Xylene Soluble (XS) total
%
11.2
8
11.9
13
Characterization
Flexural Modulus
MPa
920
1143
957
740
Izod impact @23° C.
kJ/m 2
5.2
4.1
4.2
nm
Tens. Str.@ yield
MPa
25.5
29.6
26.4
nm
Elong.@ break
%
854
478
985
nm
HAZE (plaque 1 mm)
%
10.3
14.8
11.3
9.8
Tm
° C.
148
152.5
151
149.7
Tc
° C.
114
115.9
117
114.8
Hm
J/g
77
84.3
79
71.2
XS * C2A-MFR/C2B
28.9
16
16.8
36.3
(B)/C2B
2.1
2
1.9
1.4
C2 = ethylene;
C3 = propylene;
nm = not measured
From table 2 clearly results that the composition according to the present invention shows an improved flexural modulus with the about same value of haze. | Propylene polymer compositions comprising:
A) from 70 wt % to 95 wt %, of a random copolymer of propylene with ethylene, containing from 1.5 wt % to 4.5 wt %, of ethylene derived units, having a content of fraction insoluble in xylene at 25° C. of not less than 93%; B) from 5 wt % to 35 wt %, of a copolymer of propylene with ethylene, containing from 7.0 wt % to 17.0 wt % of ethylene derived units;
the sum A+B being 100;
wherein the melt flow rate, MFR. (Melt Flow Rate according to ASTM 1238, condition L, i.e. 230° C. and 2.16 kg load) ranges from 40 g/10 min and 130 g/10 min; and wherein the relation (I) is fulfilled:
10< XS*C 2 A −MFR/ C 2 B <30 (I)
wherein XS is the wt % of xylene soluble content at 25° C. of the total composition; C2A is the wt % of ethylene derived units content of component A; MFR is the melt flow rate of the total composition; C2B is the wt % of ethylene derived units content of component B. | 2 |
BACKGROUND OF THE INVENTION
The present invention relates in general to well logging detectors of the scintillation crystal type, and more particularly to a ruggedized detector characterized by its high shock resistance. The detector in accordance with the invention is especially useful in measurement-while-drilling (MWD) applications wherein high shock loads on the detector are common.
U.S. Pat. Nos. 4,004,151; 4,158,773; 4,360,733; 4,383,175 and 4,764,677 all illustrate well logging detectors of the scintillation crystal type. These U.S. patents are owned by the assignee of the present invention, and are incorporated by reference herein in their entireties.
In detectors of the type disclosed in the above-noted patents, a cylindrical scintillation crystal, such as a thallium-activated alkali halide (e.g. sodium iodide) crystal, is coaxially contained within, and is hermetically sealed within, a cylindrical metal housing typically formed from stainless steel. One end of the housing has a light transparent window portion. When ionizing radiation, such as gamma radiation, impinges on the crystal,light pulses, i.e. photons, are generated within the crystal. These radiation induced light pulses exit the detector via the window portion of the detector housing. The exiting light pulses in turn are detected by an associated photomultiplier tube whose output is an electrical signal that can then be analyzed to determine the characteristics of the radiation impinging on the scintillation crystal.
In four of the above noted patents, namely U.S. Pat. No. 4,004,151; 4,360,733, 4,383,175 and 4,764,677, a compression spring applies a biasing force against one end of the crystal to maintain the other end of the crystal in optical coupling relationship with the window portion of the detector housing. The compression spring is necessary to accommodate substantial thermal expansion and contraction of the crystal within the detector housing that occurs during well logging. Typically, aluminum oxide powder, which is light reflective, is packed between the outer surface of the cylindrical crystal and the inner surface of the cylindrical housing. The packed powder serves to support and maintain the crystal at its coaxial position within the housing. It also acts as a shock absorber to protect the crystal.
Should the crystal move away from and separate from the window portion of the detector as a result of shock forces on the detector, the aluminum oxide powder could migrate between the scintillation crystal and window portion thus deleteriously affecting optical coupling therebetween. To preclude movement of the crystal away from the window portion of the detector, the aforementioned compression spring applies a large magnitude biasing force, for the most strenuous shock environment, on the order of 1,000 times the weight of the crystal, i.e. for a 1,000 g tolerant detector--1,000 times the crystal mass. For example, a one pound crystal having a two inch diameter would have applied to its nonwindow end a spring force of approximately 330 psi. High shock forces on the detector tending to move the crystal away from the window portion are thus resisted by the compressed biasing spring.
Problems arise due to the high biasing forces required to maintain the optical coupling interface between the crystal and the window portion. First, the high biasing force applied to the crystal is necessarily transferred and applied to the window portion. Thus, both the crystal and the window portion are under stress induced by the biasing spring, and can fail especially under the high-thermal transients frequently experienced during well logging. Secondly, shock induced movement of the crystal against the window portion, as opposed to away from it, can blow out the window portion and/or fracture the crystal which in effect is rammed against the window under such shock induced movement. This is because the force on the crystal and window portion are the combination of the spring force and the shock induced inertial force or g-force of the crystal against the window portion. Also, under shock induced vibrations, the packed aluminum oxide powder can shift inside of the detector so as not to properly support the crystal. The shifting powder can also grind detector components.
The present invention substantially minimizes the abovenoted problems, and provides a highly ruggedized, shock resistant detector.
SUMMARY OF THE INVENTION
A well logging detector has a housing with a light transparent window portion. A scintillation member contained within the housing generates light in response to ionizing radiation impinging on it. A biasing means applies a biasing force against the scintillation member to hold it against, and optically couple it to, the window portion of the housing wherein the light generating within the housing member is transmitted to the exterior of the housing via the window portion.
In accordance with the present invention, the biasing force is weak enough to allow the scintillation member to move away from, and optically decouple and physically separate from, the window portion in response to shock forces on the detector. The biasing means, subsequent to such shock induced decoupling, moves the scintillation member back against the window portion to a re-establish optical coupling therebetween.
In a preferred form of the invention, the biasing means is constituted by a compression spring that applies a biasing force to the crystal not greater than 150 times the crystal weight and preferably about 50 times the crystal weight. Also, the well logging detector of the invention can include a light transparent, shock absorbent pad sandwiched between the window portion of the housing and the scintillation member, wherein the pad is separable from the window portion and the scintillation member. Both sides of the pad can be wetted with a light transparent liquid which enhances the ability of the scintillation member to optically recouple with the window portion subequent to shock induced decoupling of the optical interface area between the scintillation member and the window portion.
A further feature of the present invention includes the provision of an elongated tubular member contained within the housing, the tubular member being formed of potting material. The scintillation member in the preferred form of an elongated crystal is located within the interior of, and is supported by, the tubular member of potting material such that the scintillation crystal can slide back and forth along its longitudinal axis within the tubular member. Sliding movement of the scintillation crystal back and forth within the tubular member of potting material is enhanced by the provision of a layer of light reflective material such as polytetraflouroethylene tape that is wound about the axial length of the crystal. The use of potting material also eliminates the heretofore noted problem of shifting of packed aluminum oxide powder.
The well logging detector in accordance with the present invention has been found to be highly resistive to shock forces on the detector wherein it can be used in the high shock environment of measurement-while-drilling (MWD) applications.
BRIEF DESCRIPTION OF THE DRAWINGS
A fuller understanding of the invention may be held by referring to the following description and claims taken in conjunction with the accompanying drawing wherein:
FIG. 1 is a longitudinal cross-section view of a well logging detector of the scintillation crystal type in accordance with the present invention; and
FIG. 2 is an enlarged sectional view of the detector illustrated in FIG. 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference to FIG. 1, a well logging detector 10 of the scintillation crystal type is illustrated. The general shape of the detector 10 is that of a cylinder lying along an axis X-X as illustrated. The detector 10 includes an elongated housing formed from a metal tube 12 of for example stainless steel or other high strength alloy. One end of the metal tube 12 is closed by a window portion 14 comprised of an annular, window retaining ring 16, of stainless steel or the like, which carries a circular disc-shaped glass window 18. The other end of the metal tube 12 is closed by a metal end cap 20 as illustrated, the metal end cap also being formed from stainless steel or the like.
The window portion 14 and the end cap 20 are fixed to their respective ends of the tube 12 by means of weld seams 17, 22 that circumferentially extend about the respective ends of the detector 10 as illustrated. The resultant housing formed by the tube 12, the window portion 14 and the end cap 20 constitute a hermetically sealed (air tight) structure containing the operating elements of the detector 10. Details as to the welding of the window portion 14 and the end cap 20 to the ends of the tube 12 are set forth in the aforementioned U.S. Pat. No. 4,383,175. This patent also discloses the means and method for mounting the glass window 18 within the annular ring 16 so as to establish a glass-to-metal seal interface between them.
With further reference to FIG. 1, the detector 10 contains within it a scintillation member in the illustrated form of a scintillation crystal 30. The crystal 30 is for example a thallium-activated alkali halide, e.g. sodium iodide, crystal which is well known in the art. The illustrated crystal is in the shape of a cylinder and has a front end face 32 and a rear end face 34, the elongated crystal being coaxially positioned along longitudinal axis X-X as illustrated. As is well known in the art, ionizing radiation penetrating the housing constituted by housing elements 12, 14 and 20 will impinge on the crystal 30 and cause it to scintillate, that is cause it to generate photons of a particular wavelength in response to the ionizing radiation of a particular type. The photons generated within the crystal 30 passed to the exterior of the detector 10 via the glass window 18 which is transparent to the photons. By transparent it is to be understood that the glass window 18 is transparent to the wavelength of the photons generated and not necessarily transparent to the visible light spectrum. For example, the generated photons could be ultra-violet radiation as opposed to visible light. Therefore, the glass window 18 could be translucent to visible light and yet transparent to the ultraviolet radiation of interest being generated by the scintillation memebr 30.
In addition to the front end face 32 and the rear end face 34, the crystal 30 provides an outer surface of revolution 36 which extends along the length of the crystal. As is known in the art, the surfaces 34, 36 have applied to them a light reflective material so that, to the greatest extent possible, scintillation generated photons exit the crystal 30 via its front end face 32. The light reflecting material applied to the rear end face 34 can be in the form of one or more layers 60 of light reflective polytetraflouroethylene tape. In a similar fashion, and with reference to FIG. 2, the outer surface 36 of the crystal 30 can be wrapped by several layers 54 of polytetraflouroethylene tape, whose outermost layer in turn is wrapped and covered by a layer 52 of metal foil tape. The provision of light reflective material on the surfaces 34, 36 of the crystal 30 is more fully disclosed in aforementioned U.S. patent 4,764,677.
Located between an inner surface 15 of the window portion 14 and the front end face 32 of the crystal 30 is an elastomeric pad, that is formed by casting, prior to assembly of the detector 10, from a transparent silicone based material such as Dow Corning No. 186 silicone rubber which is manufactured and sold by the Dow Corning Company, The pad 40 is rubberlike in consistency and, as shown most clearly in FIG. 2, provides an inner face 42 and an outer face 44. Preferably the inner and outer face 42, 44 are covered by a thin film of liquid such as a high viscosity vacuum grease a ("Dow Corning Vacuum Grease") manufactured and sold by the Dow Corning Company. The liquid on the surfaces 42, 44 function as a wetting agent so as to enhance optical coupling between the front end face 32 of the crystal and inner face 42 of the pad 40, and in a similar manner between inner surface 15 of the window portion 14 and the outer face 44 of the pad 40.
In accordance with the present invention, both the front end face 32 of the crystal 30 and the inner surface 15 of the window portion 14 are separable from the pad 40. In effect, the crystal 30, the pad 40 and the window portion 14 can, by design, physically decouple from each other. Such decoupling is possible because, with reference to FIG. 1, the crystal 30 is longitudinally movable back and forth along axis X-X in response to shock forces on the detector 10 tending to cause the crystal 30 to move away from the window portion 14. To maintain optical coupling between the crystal 30 and the window portion 14 during normal operating conditions, a biasing means in the form of a compression spring 68 is provided between the inter surface of the end cap 20 and the rear face 34 of the scintillation crystal 30. It can be seen that one end of the compressed spring 68 bears aginst the end cap 20, while its other end bears aginst the metal backing plate 64 which in turn bears against an elastomeric precast elastomeric pad 62 made for example from the aforementioned Dow Corning No. 186 silicone rubber material. The elastomeric pads 40, 62 serve, as a part of their function, as cushioning mebers to protect the crystal 30 against shock forces.
The outer surface 36 of the scintillation crystal 30 is supported in coaxial position within the detector 10 by means of a tubular member 50 formed of potting material having elastomeric characteristics. The potting material formed tubular member 50 is generally fixed in position relative to the metal tube 12 forming a portion of the housing of the detector 10. With reference to FIG. 2, the tape layers 52, 54 are also generally fixed in relation to tubular member 50 so that elements 12, 50, 52 and 54 function together to comprise, in effect, a cylinder block within which crystal 30 can slide or reciprocate back and forth to a limited degree in response to high shock forces on the detector 10.
In accordance with the invention, the biasing force provided by compression spring 68 is weak enough to allow the crystal 30 to move away and pysically separate from the window portion 14 so as to optically decouple from it. Preferably, the biasing force applied to the rear end face 34 of the crystal 30 is not greater than 150 times the crystal weight and is preferably on the order to 50 times the crystal weight. By design, the biasing force is substantially less than the maximum shock "g" load times the crystal weight. This is contrary to the four patented prior art detectors as noted above wherein spring forces well over 150 times the crystal weight are utilized in order to preclude optical decoupling of a scintillation crystal from its associated window portion of its housing under high shock forces. Because of the weak biasing force provided by compression spring 68, shock forces tending to move or ram the crystal 30 against the window portion 14 are not supplemented by high biasing forces from the spring 68. The weak biasing force from the spring 68 only needs to move the crystal 30 back towards the window portion 14 so as to re-establish the optical coupling therebetween, the elastomeric pad 40 with its wetted surfaces 42, 44 re-establishing optical coupling upon return of the crystal 30 to its normal position within the metal tube 12 of the detector housing as illustrated in FIGS. 1 and 2.
The detector as set forth above has been found to be extremely tolerant to high shock loads since, instead of fighting such loads to maintain optical coupling between the scintillation crystal and the window portion of the housing, optical decoupling is permitted by design and means are provided for re-establishing optial coupling, such means being constituted by the relatively weak biasing force provided by the compression spring 68 and the axial sliding of the crystal 30 within the tubular member 50. Because the detector 10 does not include any packed aluminum oxide powder as was the common practice in prior art detectors as discussed earlier, no contamination of the separated and decoupled optical interface between the crystal and the window portion 14 can occur. Also, the problems of powder shifting and grinding due to vibration is eliminated. Also, the elastomeric members 40, 50, 62, which can all be formed for example from the aforementioned Dow Corning No. 186 silicone rubber or the like, insulate the crystal 30 from normal shock forces not strong enough to decouple the crystal 30 as noted earlier. By design, the biasing spring holds the crystal in place against the window against such normal shock forces, while it allows optical decoupling under high shock loads as noted earlier.
The detector 10 in accordance with the present invention can been assembled by first spirally wrapping the crystal about its surface 36 with the earlier noted tape layers 54, 52. The wrapped crystal 30 is then inserted into the metal tube 12. With the crystal 30 coaxially positioned within the metal tube 12, uncured potting material 50 is poured around the outside of the wrapped crystal 30 to provide tubular member 50, the metal foil layer 52 preventing the potting material from migrating into and otherwise deleteriously affecting the light reflective tape layers 54. The pad 40 with both surfaces 42, 44 wetted by the aforementioned vacuum grease is then applied to or in effect stuck on to the front end face 32 of the crystal 30, so that the inner surface 42 of the pad 40 contacts and optically couples to the front end face 32 of the crystal. The window portion 14 is then put in place so that pad surface 44 contacts the inside surface 15 of the window portion 14. The window portion 14 is then welded to the front end of the tube 12 as illustrated. Subsequently, the reflective material 60, in the form of one or more layers of tape or film, is applied to the rear end face 34 of the crystal 30. The precast pad 62 is then inserted into the metal tube 12, and then the backing plate 64 is inserted as illustrated. As a final step, the compression spring 68 is inserted and then the end cap 20 is pushed into the end of the metal tube 12 to compress the spring 68 to a predetermined degree (for providing the "weak" biasing force) wherein welded seam 22 is provided to seal the detector 10 and to fix the end cap 20 to the end of the metal tube 12. It is to be noted that the assembly procedure for the detector 10 occurs in the manner that will provide an inert atmosphere within the detector 10 in accordance with the teachings of the aforementioned U.S. Pat. No. 4,764,677.
While the invention has been shown and described with respect to a particular embodiment thereof, this is for the purpose of illustration rather than limitation, and other variations and modifications of the specific embodiment herein shown and described will be apparent to those skilled in the art all within the spirit and scope of the invention. Accordingly, the patent is not to be limited in scope and effect to the specific embodiment herein shown and described nor in any other way that is inconsistent with the extent to which the progress in the art has been advanced by the invention. | A well logging detector includes an elongated scintillation crystal having one end biased against and optically coupled to a transparent window portion of the detector housing. The biasing force on the crystal is provided by a compression spring located at and bearing against the other end of the crystal. The biasing force applied to the crystal by the spring is weak enough to allow the crystal to move away from and optically decouple from the window portion in response to shock forces on the detector. Subsequent to such shock induced decoupling, the biasing spring moves the crystal against the window portion to re-establish optical coupling therebetween. Such a biasing structure precludes excessive axial loading of the crystal by shock forces tending to move the crystal against the window as opposed to away from it. Such a shock resistant detector is especially well suited to measurement-while-drilling (MWD) applications. | 4 |
FIELD OF THE INVENTION
The present invention relates generally to article, load, or package wrapping machines, apparatus, or systems, and more particularly to a new and improved mechanism or system which is to be utilized in conjunction with such article, load, or package wrapping machines, apparatus, or systems whereby in effect the attachment of the leading edge portion of the wrapping film to the article, load, or package at the commencement of an article, load, or package wrapping cycle, as well as the detachment or severance of the trailing edge portion of the wrapping film from the article, load, or package at the termination of the article, load, or package wrapping cycle, can be achieved in a semiautomatic manner obviating the need for operator personnel to physically, personally, or manually attach or sever the leading and trailing edge portions of the wrapping film to or from the article, load, or package, respectively.
BACKGROUND OF THE INVENTION
Article, load, or package wrapping machines, apparatus, or systems for wrapping articles, loads, or packages within a suitable wrapping film are of course well-known. In accordance with such article, load, or package wrapping machines, apparatus, or systems, a roll of packaging film is normally mounted upon a film roll carriage, and the film roll carriage is movably mounted, for example, upon an upstanding mast or track member, such that the film roll carriage, having the roll of wrapping film mounted thereon, can be vertically moved between uppermost and lowermost positions while also undergoing relative rotatable movement with respect to the article, load, or package. In this manner, spiral wrapping of the film upon the article, load, or package is able to be achieved in a well-known manner. In order to minimize article, load, or package wrapping cycle time, and therefore maximize article, load, or package wrapping production, that is, the number of articles, loads, or packages that can be wrapped or packaged within a predetermined period of time, it is desirable to, in effect, automate the article, load, or package wrapping cycle as much as possible. One operative part or section of such article, load, or package wrapping cycle in which strides have sought to have been made in order to enhance the automation of the wrapping cycle resides in the attachment or securing, and the detachment or severing, of the end portions of the wrapping film onto and from the particular article, load, or package being wrapped. An automated system of this type is disclosed, for example, within U.S. Pat. No. 5,572,850 which issued to Lancaster, III et al. on Nov. 12, 1996. In accordance with the operative system disclosed within such patent, in order to sever or separate a trailing end portion of the wrapping film 34 , which is already wrapped around a load 32 , a puncturing device 62 having a plurality of sharp pins 64 is activated such that the sharp pins 64 puncture the trailing end portion of the wrapping film in order to effectively weaken the same. The film delivery or dispensing drive motor 54 is no longer driven, however, the turntable 58 , upon which the packaged or wrapped load is disposed, continues to rotate. Consequently, the weakened film is tensioned and stretched, the holes or perforations increase in size, and eventually, the film tears at the weakened sites defined by the punctured holes.
While the aforenoted system is quite satisfactory and has been commercially successful, the system exhibits several operational drawbacks or disadvantages. Firstly, the system is relatively costly and complex. For example, as disclosed within the noted patent, in order to achieve the proper operation of the system, at least three different timer devices or mechanisms must be incorporated or implemented into the system. In particular, a first timer 76 a is required in order to decelerate the film delivery drive motor 54 and turntable 58 in preparation for the initiation of the hole puncturing operation to be performed upon the trailing end portion of the wrapping or packaging film, a second timer 76 b is required for controlling the solenoid 68 in order to in turn control the actuation of the puncturing device 62 , and a third timer 76 c is required for controlling the termination of the film delivery drive motor 54 such that the aforenoted tensioning and stretching of the punctured wrapping or packaging film occurs in order to achieve the torn separation of the trailing edge portion of the wrapping or packaging film from the roll of wrapping or packaging film. Secondly, while the semi-automatic wrapping apparatus or system disclosed within the aforenoted patent is utilized to detach, terminate, or sever the trailing end portion of the wrapping or packaging film from the roll of wrapping or packaging film, there is no corresponding means or mechanism for securing, initiating, or attaching the leading end portion of the wrapping or packaging film to the article, load, or package to be wrapped or packaged in a semi-automatic operational mode. More particularly, in accordance with the disclosure of the aforenoted patent, in order to initiate a new wrapping or packaging cycle, an operator must grasp the free leading end portion 70 of the wrapping or packaging film, which is complementary to the trailing end portion of the wrapping or packaging film as formed by means of the aforenoted tearing or separating process facilitated by the puncturing, tensioning, and stretching of the film, and manually apply or secure such free leading end portion 70 of the wrapping or packaging film to the particular article, load, or package to be subsequently wrapped or packaged.
Accordingly, a need exists in the art for a new and improved mechanism or system which can be utilized in conjunction with article, load, or package wrapping apparatus, machines, or systems whereby in effect the attachment of the leading edge portion of the wrapping film to the article, load, or package at the commencement of an article, load, or package wrapping cycle, as well as the detachment or severance of the trailing edge portion of the wrapping film from the article, load, or package at the termination of the article, load, or package wrapping cycle, can be achieved in a semi-automatic manner obviating the need for operator personnel to physically, personally, or manually attach or sever the leading and trailing end portions of the wrapping film to or from the article, load, or package, respectively.
OBJECTS OF THE INVENTION
Accordingly, it is an object of the present invention to provide a new and improved mechanism or system which is to be utilized in conjunction with package, load, or article wrapping machines, apparatus, or systems for implementing the attachment or securement of a leading end portion of a wrapping or packaging film to an article, load, or package to be wrapped or packaged so as to prepare for the commencement of a film wrapping or packaging operation or cycle, as well as the detachment or severance of a trailing end portion of the wrapping or packaging film from the wrapped or packaged article, load, or package upon termination of the wrapping or packaging operation or cycle.
Another object of the present invention is to provide a new and improved mechanism or system which is to be utilized in conjunction with package, load, or article wrapping machines, apparatus, or systems for implementing the attachment or securement of the leading end portion of the wrap-ping or packaging film to the article, load, or package to be wrapped or packaged so as to prepare for the commencement of the film wrapping or packaging operation or cycle, as well as the detachment or severance of the trailing end portion of the wrapping or packaging film from the wrapped or packaged article, load, or package upon termination of the wrapping or packaging operation or cycle, and which effectively overcomes the various operational drawbacks or disadavantages characteristic of the prior art systems.
An additional object of the present invention is to provide a new and improved mechanism or system which is to be utilized in conjunction with package, load, or article wrapping machines, apparatus, or systems for implementing the attachment or securement of the leading end portion of the wrapping or packaging film to the package, load, or article to be wrapped or packaged so as to prepare for the commencement of the film wrapping or packaging operation or cycle, as well as the detachment or severance of the trailing end portion of the wrapping or packaging film from the wrapped or packaged article, load, or package upon termination of the wrapping or packaging operation or cycle, and which is relatively simple in structure and economical to produce.
A further object of the present invention is to provide a new and improved mechanism or system which is to be utilized in conjunction with package, load, or article wrapping machines, apparatus, or systems for implementing the attachment or securement of the leading edge portion of the wrapping film to the article, load, or package to be wrapped or packaged so as to prepare for the commencement of the film wrapping or packaging operation or wrapping cycle, as well as the detachment or severance of the trailing edge portion of the wrapping or packaging film from the package, load, or article upon termination of the article, load, or package wrapping or packaging operation or cycle, in a semiautomatic manner thereby obviating the need for operator personnel to physically, personally, or manually attach or sever the leading and trailing end portions of the wrapping film to or from the article, load, or package, respectively.
SUMMARY OF THE INVENTION
The foregoing and other objectives are achieved in accordance with the teachings and principles of the present invention through the provision of a new and improved mechanism or system which comprises a vertically upstanding stanchion or standard upon which a proximal end portion of an actuating arm is pivotally mounted. The actuating arm is pivotally movable between a first inoperative retracted position at which the actuating arm is disposed remote from the flow path of the wrapping or packaging film as the wrapping or packaging film is dispensed from the roll of wrapping or packaging film and wrapped around a load, article, or package disposed at a wrapping station, and a second operative extended position at which the actuating arm is disposed adjacent to the flow path of the wrapping or packaging film. A vertically oriented support plate is fixedly mounted upon a distal end portion of the actuating arm, and a first clamping plate is fixedly mounted upon an upper portion of the support plate. The first clamping plate has an electrically energizable cutting wire mounted thereon, and a second clamping plate is movably mounted upon the vertically oriented support plate. More particularly, the second clamping plate is movable between a first lowered inoperative position, and a second elevated operative position at which the second clamping plate is adapted to cooperate with the first clamping plate so as to clamp a portion of the wrapping or packaging film therebetween.
Accordingly, when a wrapping or packaging operation or cycle is to be terminated, the actuating arm is moved from its first inoperative retracted position remote from the wrapping or packaging film flow path to its second operative extended position adjacent to the wrapping or packaging film flow path, and the second clamping plate is moved from its first lowered inoperative position to its second elevated operative position so as to cooperate with the first clamping plate and thereby clamp a portion of the wrapping or packaging film therebetween. At this time, the cutting wire is energized, and the clamped portion of the packaging or wrapping film is thereby severed. In this manner, the severed trailing end portion of the packaging or wrapping film extending from the packaged or wrapped article, load, or package is able to be secured to the packaged or wrapped article, load, or package, while the severed leading end portion of the packaging or wrapping film extending from the roll of wrapping or packaging film is held or maintained between the first and second clamping plates in preparation for the commencement of a new packaging or wrapping operation or cycle to be performed upon or in connection with a new article, load, or package to be wrapped or packaged when a new article, load, or package to be wrapped or packaged is conveyed to or deposited at the wrapping or packaging station.
Subsequently, the actuating arm is moved or returned to its remote or retracted position with respect to the packaging or wrapping film flow path, and when a new article, load, or package to be wrapped or packaged has been conveyed to or deposited at the wrapping or packaging station, the actuating arm, still having the leading end portion of the wrapping or packaging film held or maintained between its clamping plates, is then moved again to its operative extended position adjacent to the packaging or wrapping film flow path. When a new packaging or wrapping operation or cycle has been partially commenced in connection with the new article, load, or package, the second lower clamping plate is moved downwardly away from the first upper clamping plate such that the leading end portion of the packaging or wrapping film held or maintained between the first and second clamping plates is now released, the new packaging or wrapping operation or cycle being performed upon or in connection with the new article, load, or package is continued, and the actuating arm is moved from its second operative extended position adjacent to the wrapping or packaging film flow path so as to again be returned to its first inoperative retracted position remote from the packaging or wrapping film flow path. When the new packaging or wrapping operation or cycle is to be terminated, the actuating arm will once again be moved from its first inoperative retracted position back to its second operative extended position adjacent to the wrapping or packaging film flow path in preparation for a clamping and severing operation whereby the operating cycles are cyclically repeated.
BRIEF DESCRIPTION OF THE DRAWINGS
Various other objects, features, and attendant advantages of the present invention will be more fully appreciated 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 front perspective view of a new and improved mechanism or system which is to be utilized in conjunction with package, load, or article wrapping machines, apparatus, or systems for implementing the attachment or securement of the leading edge portion of the wrapping film to the article, load, or package to be wrapped or packaged so as to prepare for the commencement of the film wrapping or packaging operation or wrapping cycle, as well as the detachment or severance of the trailing edge portion of the wrapping or packaging film from the package, load, or article upon termination of the article, load, or package wrapping or packaging operation or cycle, in a semi-automatic manner thereby obviating the need for operator personnel to physically, personally, or manually attach or sever the leading and trailing end portions of the wrapping film to or from the article, load, or package, respectively, the actuating arm being disclosed, for example, at its extended position; and
FIG. 2 is a rear perspective view of the new and improved mechanism or system as disclosed within FIG. 1 wherein the actuating arm is disclosed at its retracted position.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings, and more particularly to FIGS. 1 and 2 thereof, a new and improved mechanism or system, which is to be utilized in conjunction with package, load, or article wrapping machines, apparatus, or systems for implementing the attachment or securement of a leading edge portion of the wrapping film to the article, load, or package to be wrapped or packaged so as to prepare for the commencement of the film wrapping or packaging operation or wrapping cycle, as well as the detachment or severance of a trailing edge portion of the wrapping or packaging film from the package, load, or article upon termination of the article, load, or package wrapping or packaging operation or cycle, in a semi-automatic manner so as to obviate the need for operator personnel to physically, personally, or manually attach or sever the leading and trailing end portions of the wrapping film to or from the article, load, or package, respectively, is disclosed and is generally indicated by the reference character 10 . More particularly, the new and improved mechanism or system 10 is seen to comprise a base member 12 upon a first end of which there is fixedly mounted an upstanding support bracket 14 . The upstanding support bracket 14 is provided with a pair of vertically spaced bracket lugs or ears 16 for fixedly mounting a cylinder member 18 of an electrical linear actuator assembly 20 . The electrical linear actuator assembly 20 is seen to further comprise an electrical linear actuator drive motor 22 which is mounted upon a support block 24 , and the electrical linear actuator drive motor 22 is rotatably engaged with a rotatably driven member 26 which is also mounted upon the support block 24 and which forms part of a combination rotary-rectilinear conversion drive unit 28 .
The combination rotary-rectilinear conversion drive unit 28 , in turn, includes a piston member 30 which is operatively engaged with the rotatably driven member 26 so as to be linearly movable interiorly of and with respect to the external cylinder member 18 in response to rotational movements of the rotatably driven member 26 . In this manner, as the electrical linear actuator drive motor 22 is rotated in a first direction, rotatably driven member 26 is rotated in an opposite direction so as to, for example, cause the piston member 30 to be linearly extended with respect to the cylinder member 18 , whereas when the electrical linear actuator drive motor 22 is rotated in a second direction, which is opposite to its first rotational or angular direction, rotatably driven member 26 is rotated in a second opposite direction so as to, for example, cause the piston member 30 to be linearly retracted with respect to the cylinder member 18 . It is further noted that the free end portion of the piston member 30 is integrally provided with a connector plate 32 , and that the connector plate 30 is adapted to be pivotally secured or attached to a lug or ear member 34 by means of a connector pin 36 . The lug or ear member 34 is fixedly mounted upon and projects radially outwardly from a lower end portion of a vertically extending externally splined shaft 38 . The vertically extending externally splined shaft 38 is internally housed for rotational or angular movement within a vertically oriented stanchion 40 which is fixed at its lower end portion upon the base member 12 . The upper end portion of the vertically extending externally splined shaft 38 projects vertically outwardly from and above the upper end portion of the stanchion 40 , and in this manner, the upper end portion of the externally splined shaft 38 is adapted to be internally housed within and splinedly mated with an internally splined annular cap member 42 . The internally splined cap member 42 is integrally formed upon a proximal end of a horizontally extending actuating arm 44 , and the horizontally extending actuating arm 44 is adapted to undergo pivotal movement in accordance with the double arrowhead CW-CCW around the vertical axis 46 defined by means of the upwardly extending externally splined shaft 38 .
More particularly, it can be readily appreciated that when the electrical linear actuator assembly 20 is energized such that the piston member 30 is moved to its extended position as shown in FIG. 1, actuating arm 44 is rotated in the counterclockwise direction around vertical axis 46 as denoted by arrow CCW so as to be moved to its extended position as shown in FIG. 1 through means of the pivotal or rotational movements of the lug or ear member 34 , upstanding externally splined shaft 38 , and annular internally splined cap member 42 . Conversely, when the electrical linear actuator assembly 20 is energized such that the piston member 30 is moved to its retracted position as shown in FIG. 2, actuating arm 44 is rotated in the clockwise direction around vertical axis 46 as denoted by the arrow CW so as to be moved to its retracted position as shown in FIG. 2 through means of the opposite pivotal or rotational movements of the lug or ear member 34 , upstanding externally splined shaft 38 , and annular internally splined cap member 42 .
A vertically oriented support plate 48 is fixedly mounted upon the distal end portion of the actuating arm 44 through means of a mounting plate 50 , and as best seen in FIG. 1, a first film clamping plate 52 is fixedly mounted upon an upper portion of the front face of the support plate 48 , while a second film clamping plate 54 is adapted to be movably mounted upon the front face of the support plate 48 so as to be disposed, for example, either at a first lowermost position with respect to the upper clamping plate 52 , or at a second uppermost position with respect to the upper clamping plate 52 . It can readily be appreciated then that when the second film clamping plate 54 is disposed at its first lowermost position with respect to the first film clamping plate 52 , the clamping plates 52 , 54 are disposed at relative OPEN positions with respect to each other such that a portion of a wrapping or packaging film can be interposed therebetween in preparation for a clamping operation to be performed upon such portion of the wrapping or packaging film, or that a portion of the wrapping or packaging film, which has been previously clamped between the clamping plates 52 , 54 can now be released from its clamped or retained position or state between the clamping plates 52 , 54 . Alternatively, of course, when the second film clamping plate 54 is disposed at its second uppermost position with respect to the first film clamping plate 52 , the clamping plates 52 , 54 are disposed at relative CLOSED positions with respect to each other such that a portion of a wrapping or packaging film interposed between the clamping plates 52 , 54 is either clamped in preparation for a film severing operation to be performed upon such portion of the wrapping or packaging film, or that a portion of the wrapping or packaging film, which has been previously severed, is retained between the clamping plates 52 , 54 in preparation for the commencement of a new wrapping or packaging operation or cycle.
Continuing further, in order to movably mount the second film clamping plate 54 upon the vertically oriented support plate 48 , a first lower mounting block 56 is fixedly mounted upon a lower portion of the rear surface of the vertically oriented support plate 48 , while a second upper mounting block 58 is likewise fixedly mounted upon an upper portion of the rear surface of the vertically oriented support plate 48 as best seen in FIG. 2. A vertically oriented acme screw shaft 60 is rotatably mounted within the lower and upper mounting blocks 56 , 58 , and a drive motor 62 is mounted atop the upper mounting block 58 . A vertically movable carriage 64 is mounted upon the acme screw shaft 60 , and the drive motor 62 is operatively connected to the acme screw shaft 60 such that when the drive motor 62 is energized so as to alternatively rotatably drive the acme screw shaft 60 in opposite angular or rotational directions, the carriage 64 will be accordingly driven in upward and downward directions along the acme screw shaft 60 . As best seen in FIG. 1, the vertically oriented support plate 48 is also provided with a vertically oriented through-slot 66 , and a bracket member 68 , having a substantially inverted L-shaped configuration and fixedly interconnecting a forward-facing portion of the carriage 64 to the lower clamping plate 54 , is adapted to pass through the vertically oriented slot 66 defined within the vertically oriented support plate 48 .
In this manner, it can be readily appreciated that the lower clamping plate 54 is able to be moved upwardly and downwardly between its extreme CLOSED and OPENED positions with respect to the upper fixed clamping plate 52 by means of the carriage drive system or assembly comprising drive motor 62 , lower and upper mounting blocks 56 , 58 , acme drive screw shaft 60 , carriage 64 , and connecting bracket 68 . It is further noted that, in conjunction with the aforenoted structure comprising the carriage drive system or assembly for operatively moving the lower clamping plate 54 , and in order to permit the lower clamping plate 54 to be moved into gripping or clamping contact with the upper clamping plate 52 , the upper clamping plate 52 is provided with a through-slot 70 . Through-slot 70 can therefore accommodate that part of the connecting bracket 68 , which projects through the through-slot 66 defined within the vertically oriented support plate 48 and which connects to the lower clamping plate 54 , when the lower clamping plate 54 is moved upwardly to its uppermost clamping position with respect to upper clamping plate 52 . It is lastly noted that upper clamping plate 52 is provided with an electrically energizable hot wire or cutting wire mechanism 72 which, when suitably energized, can cut or sever that portion of the wrapping or packaging film which is gripped or clamped between the upper and lower clamping plates 52 , 54 when the lower clamping plate 54 has been moved to its uppermost clamping position with respect to the upper clamping plate 52 .
Having now described all of the structural components comprising the new and improved mechanism or system 10 which is to be utilized in conjunction with package, load, or article wrapping machines, apparatus, or systems for implementing the attachment or securement of a leading edge portion of the wrapping film to the article, load, or package to be wrapped or packaged in preparation for the commencement of a film wrapping or packaging operation or wrapping cycle, as well as the detachment or severance of a trailing edge portion of the wrapping or packaging film from the package, load, or article upon termination of the article, load, or package wrapping or packaging operation or cycle, the operation of the new and improved mechanism or system 10 will now be described. Assuming that a particular article, load, or package has been previously disposed at a wrapping station, not shown, and that, for example, a rotatable wrapping arm of a wrapping machine, also not shown, has been rotated around the wrapping station in order to spiral wrap the article, load, or package, then upon termination of the wrapping operation or cycle, rotational movement of the wrapping arm is terminated. The electrical linear actuator drive motor 22 is now energized whereby, through means of rotary-linear conversion drive unit 28 , piston 30 , and driven splined members 38 , 42 , actuating arm 44 is now moved from its retracted position as shown in FIG. 2 toward its extended position as shown in FIG. 1 . When the actuating arm 44 has reached its fully extended position, which may be predetermined, for example, by means of a suitable proximity switch, not shown, energization of the electrical linear actuator drive motor 22 is terminated and the upper and lower clamping plates 52 , 54 are now disposed substantially adjacent to the wrapping or packaging film flow path or locus as determined by means of the wrapping machine wrapping arm, not shown, whereby the upper and lower clamping plates 52 , 54 will be disposed, in effect, above and below a portion of the wrapping or packaging film which extends from the wrapped or packaged article, load, or package to the roll of wrapping or packaging film disposed upon a carriage member, not shown, mounted upon the wrapping machine wrapping arm, also not shown, in a manner well-known in the art.
Accordingly, drive motor 62 can now be energized so as to move the carriage 64 , and therefore the lower clamping plate 54 attached thereto, from its lowermost position toward its uppermost position with respect to the upper clamping plate 52 . In this manner, that portion of the wrapping or packaging film which is interposed between the upper and lower clamping plates 52 , 54 is now vertically compressed or crimped together in a clamped or gripped fashion between the upper and lower clamping plates 52 , 54 , and the drive movement of the drive motor 62 , and therefore the upward movement of the lower clamping plate 54 , is then terminated by means of another suitable proximity switch, not shown. Hot wire cutting mechanism 72 can now be energized whereby the clamped or crimped portion of the wrapping or packaging film is then severed whereby the severed trailing edge portion of the wrapping or packaging film wrapped around the particular article, load, or package, is simply applied or secured to the article, load, or package under the influence of gravity and its self-adherent properties. The corresponding or complementary severed leading edge portion of the wrapping or packaging film is still retained by the CLOSED clamping plates 52 , 54 in preparation for the commencement of a new wrapping or packaging operation or cycle to be performed upon or in connection with a new load, article, or package to wrapped or packaged.
Accordingly, electrical linear actuator drive motor 22 is again energized so as to move the actuating arm 44 from its extended position, as shown in FIG. 1, back to its retracted position, as shown in FIG. 2, in order to permit a new article, load, or package, to be wrapped or packaged, to be placed at the wrapping station. An operational START button, not shown, is then pressed by the operator upon, for example, a remote console or the like, and accordingly, the wrapping film roll carriage, not shown, mounted upon the wrapping machine wrapping arm, also not shown, is moved upwardly, for example, so as to initiate the wrapping or packaging operation or cycle at the top of the article, load, or package being wrapped or packaged. At the same time, electrical linear actuator drive motor 22 is again energized so as to again move the actuating arm 44 from its retracted position, as shown in FIG. 2, to its extended position as shown in FIG. 1 . The clamping plates 52 , 54 , still disposed at their relative CLOSED position and therefore still retaining the crimped or clamped leading end portion of the wrapping or packaging film therebetween, are therefore now disposed adjacent the packaging or wrapping film flow path or locus. The packaging or wrapping film now extends, in effect, from the clamping plates 52 , 54 to the film roll mounted upon the vertically movable carriage, not shown, disposed upon the wrapping arm, also not shown, of the wrapping machine.
At this time, the wrapping arm, not shown, of the wrapping machine is rotated through means of an angular rotation of approximately three-quarters of one revolution, or approximately 270°, and is then momentarily stopped. Drive motor 62 is then energized so as to move lower clamping plate 54 to its OPENED position with respect to upper clamping plate 52 whereby the clamped or crimped leading edge portion of the packaging or wrapping film is now released and permitted to fall under the influence of gravity whereby such leading edge portion of the packaging or wrapping film will in effect self-adhere to the new package, load, or article being wrapped. Electrical linear actuator drive motor 22 is now again energized so as to move the actuating arm 44 back to its retracted position as shown in FIG. 2 from its extended position as shown in FIG. 1, and the wrapping arm, not shown, of the wrapping machine is once again energized so as to complete the particular wrapping or packaging operation or cycle. Upon completion of the entire package, load, or article wrapping or packaging operation, rotational movement of the wrapping machine wrapping arm, not shown, is terminated, an entire operational cycle has been completed, and an entirely new operational cycle may be initiated or implemented.
Thus, it may be seen that in accordance with the principles and teachings of the present invention, there has been provided a new and improved mechanism or system, which can be utilized in conjunction with package, load, or article wrapping machines, apparatus, or systems for implementing the attachment or securement of a leading edge portion of the wrapping film to the article, load, or package to be wrapped or packaged so as to prepare for the commencement of the film wrapping or packaging operation or wrapping cycle, as well as the detachment or severance of a trailing edge portion of the wrapping or packaging film from the package, load, or article upon termination of the article, load, or package wrapping or packaging operation or cycle, in a semiautomatic manner so as to obviate the need for operator personnel to physically, personally, or manually attach or sever the leading and trailing end portions of the wrapping or packaging film to or from the article, load, or package, respectively.
Obviously, many variations and modifications 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 present invention may be practiced otherwise than as specifically described herein. | A system and method for severing a portion of a wrapping film for facilitating the detachment and attachment of trailing and leading end portions of the wrapping film from and onto loads disposed at a wrapping station in conjunction with film wrapping operations being performed upon loads being wrapped at a wrapping station comprises an actuating arm movable between retracted and extended positions and upon which a fixed clamping member and a movable clamping member are mounted such that the movable clamping member can move toward and away from the fixed clamping member so as to define therewith CLOSED and OPENED positions. Upon termination of a wrapping operation, the actuating arm is moved from its retracted position to its extended position, the clamping members are moved to their CLOSED position so as to clamp a portion of the wrapping film therebetween, and a hot-wire cutter is energized so as to sever a portion of the clamped film. A trailing end portion of the wrapping film is thus released for self-adherence to the wrapped load, while a leading end portion of the wrapping film is maintained clamped between the clamping members in preparation for self-adherence to a new load to be wrapped. When wrapping of the new load is commenced, the movable clamping member is moved to its OPENED position such that the clamped leading end portion of the wrapping film is released for self-adherence to the new load to be wrapped, and the actuating arm is returned to its retracted position. | 8 |
This application is a continuation of application Ser. No. 08/330,328, filed on Oct. 27, 1994 now abandoned.
BACKGROUND OF THE INVENTION
Field of the Invention
The invention relates to a method for suppressing vibration in the drive train of a motor vehicle, in which a variable being dependent on a speed of an engine is detected, a gradient is derived from the variable and evaluated, and a torque of the engine is reduced by varying an ignition angle if impermissible vibration is detected, wherein the torque reduction is controlled as a function of an upper and a lower threshold value for the gradient. The invention also relates to an engine control operating according to that method.
One such method, which is known from German Published, Non-Prosecuted Application DE 40 09 791 A1, serves to suppress vibration in the drive train of a motor vehicle having an engine speed which is detected by a sensor. When such vibration occurs, the engine is supplied with a correcting variable that is ascertained in a correction device, which lowers the engine torque by varying the ignition timing. The ignition timing is varied, for instance, by switching over from a first to a second ignition performance graph in an ignition control unit.
In a closed-loop control device for the engine of a motor vehicle which is also known, vibrations of the body upon vehicle acceleration are prevented by adjusting the ignition timing. To that end, the engine speed, the change in engine speed over time, and the direction of engine speed change are detected. The ignition timing read from a performance graph is corrected in accordance with the magnitude and sign (+ or -) of the change in engine speed, according to German Published, Non-Prosecuted Application DE 37 17 368 A1.
However, the vibration in the drive drain of a motor vehicle, which is also known as bucking and occurs particularly upon an abrupt transition from low partial load to full load in the lower engine speed range during an acceleration, is sensitive to closed-loop control interventions.
SUMMARY OF THE INVENTION
It is accordingly an object of the invention to provide a method and an engine control for suppressing vibration of the drive train in a motor vehicle, which overcome the hereinafore-mentioned disadvantages of the heretofore-known methods and devices of this general type and which suppress such vibration in a gentle way.
With the foregoing and other objects in view there is provided, in accordance with the invention, in a method for suppressing vibration in the drive train of a motor vehicle, which includes detecting a variable being dependent on a speed of an engine, deriving and evaluating a gradient from the variable, reducing a torque of the engine by varying an ignition angle if impermissible vibration is detected, and controlling the torque reduction as a function of an upper and a lower threshold value for the gradient, the improvement which comprises carrying out an ignition intervention reducing the engine torque if the gradient is below the lower threshold; cancelling the ignition intervention if the gradient exceeds the upper threshold value; and storing first lower threshold values in a first performance graph, and storing second higher threshold values in a second performance graph to which a switchover is made after a first tripping of an anti-bucking function.
In accordance with another mode of the invention, there is provided a method which comprises switching over back from the second performance graph to the first performance graph after a predetermined number of trippings of the anti-bucking function or after a predetermined length of time.
In accordance with an added mode of the invention, there is provided a method which comprises carrying out the ignition intervention if an acceleration enrichment is detected by the engine control.
In accordance with an additional mode of the invention, there is provided a method which comprises predetermining the lower and upper threshold values as a function of a particular gear being selected.
In accordance with yet another mode of the invention, there is provided a method which comprises calculating the gradient at low engine speeds from two successive segment times, and calculating the gradient at high engine speeds from two successive revolution times.
In accordance with yet a further mode of the invention, there is provided a method which comprises adjusting the ignition angles toward "late" upon a switchover to a torque-reducing ignition performance graph, and adjusting an amount by which the ignition angles are adjusted toward "late" in dependence on the engine speed n and an engine load.
In accordance with yet an added mode of the invention, there is provided a method which comprises assuming higher values for the lower threshold value and assuming lower values for the upper threshold value, at higher engine speeds than at lower engine speeds.
In accordance with yet an additional mode of the invention, there is provided a method which comprises delaying the adjustment of the ignition angle by a predetermined period of time.
In accordance with again another mode of the invention, there is provided a method which comprises adjusting the ignition angles back to the original value after a predetermined maximum time is exceeded, even if the upper threshold value has not been exceeded by the gradient.
With the objects of the invention in view, there is also provided, in an engine control with suppression of vibration of a drive train of a motor vehicle, including means for detecting a variable being dependent on a speed of an engine, means for deriving and evaluating a gradient from the variable, and means for reducing a torque of the engine by varying an ignition angle if impermissible vibration is detected, the improvement comprising a first performance graph in which first lower threshold values are stored, and a second performance graph in which second higher threshold values are stored and to which a switchover is made after a first tripping of an anti-bucking function.
The advantages of the invention reside particularly in the fact that with it, the dependency of the drive train vibration on the engine speed, vehicle speed, gear selected, or the applicable gear ratio and the progress of the closed-loop control process, can be taken into account as well. Other features which are considered as characteristic for the invention are set forth in the appended claims.
Although the invention is illustrated and described herein as embodied in a method and an engine control for suppressing vibration of the drive train in a motor vehicle, it is nevertheless not intended to be limited to the details shown, since various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims.
The construction and method of operation of the invention, however, together with additional objects and advantages thereof will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partly diagrammatic view and partly block circuit diagram of an engine of a motor vehicle and an engine control according to the invention;
FIG. 2 is a diagram explaining an anti-bucking function according to the invention;
FIG. 3 is a diagram showing starting thresholds used in the method of FIG. 2 as a function of engine speed; and
FIGS. 4a and 4b are parts of a flow chart of the method according to the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the figures of the drawing in detail and first, particularly, to FIG. 1 thereof, there is seen a diagrammatic and block circuit illustration of components of a motor vehicle drive train that are required for explaining the method of the invention. An engine 1 is controlled by an engine control or engine control unit 2. The engine control 2 receives engine speed values from an engine speed sensor 3, which includes a gear wheel 4 and an inductive sensor 5. The gear wheel 4 is secured to a crankshaft of the engine. The inductive sensor 5 evaluates changes in a magnetic field that are caused by teeth of the gear wheel 4 which move past the sensor. As a rule, 58 teeth are present.
In the engine control 2, the engine speed is detected and processed in the form of segment times. In a six-cylinder engine, one segment time TN corresponds to a crankshaft angle KW of 120° and is measured as the time during which teeth numbers 1-21, for instance, move past the inductive sensor 5. In a five-cylinder engine, a segment time is equivalent to a crankshaft angle KW of 144°, and in a four-cylinder engine to a crankshaft angle KW of 180°. The segment time is inversely proportional to the rpm n: TN˜1/n.
The engine control 2 also processes a signal LM that provides information on the mass of air being aspirated. This signal is furnished by a known, non-illustrated air flow rate meter in the intake manifold of the engine 1. It can also process a tachometer signal TV that provides information on the vehicle speed.
Control outputs of the engine control 2 are connected to spark plugs 6 over lines 7. In a known manner, the engine control 2 controls even more functions of the engine 1, such as the injection of fuel, but these are not shown in this case because they are unaffected by the invention. The invention suppresses vibration that arises in the drive train by means of a purposeful reduction in engine torque effected by adjusting the ignition angle toward "late" during the positive half-wave in the engine speed oscillation.
The evaluation of the engine speed is performed in the engine control 2 through segment time gradients. A segment time gradient TN -- GRD is calculated as follows:
for low engine speeds, from two successive segment times:
TN.sub.-- GRD=(TN.sub.n -TN.sub.n-1)/TN.sub.n,
and
for high engine speeds, from two successive revolution times:
TN.sub.-- GRD=(TU.sub.n -TU.sub.n-1)/TU.sub.n
The segment time gradients are freshly calculated for each segment. The boundary between the two types of calculation is at a predetermined engine speed of 1900 rpm, for instance.
The engine control 2 contains a plurality of performance graphs, of which only four are shown in this case. A first or basic ignition performance graph 10 stores the ignition angles as a function of the engine speed, and the engine load or throttle valve position. A second ignition performance graph 11 stores corresponding ignition times for a reduced engine torque. The reduction in engine torque can be performed by switching over from the ignition performance graph 10 to the ignition performance graph 11, or by calculation of ignition angles that are shifted toward "late".
First and second further performance graphs 12 and 13 contain threshold values to be explained below, for activating an anti-bucking function or in other words for tripping the reduction in torque.
In FIG. 2, the engine speed n upon vehicle acceleration and the segment time gradient TN-GRD derived from it, as well as a lower threshold value SU and an upper threshold value SO, are plotted over time t. In order to activate the anti-bucking function, the following conditions must be met.
The coolant temperature must be above a predetermined value, for instance above 300° C.
The engine speed must be in a predetermined range, for instance between 1000 and 3500 rpm.
The vehicle speed must be within a predetermined range, for instance below 50 km/h.
The engine must be operating at partial load.
No diagnostic errors must have been detected for the crankshaft, camshaft, ignition and injection.
The anti-bucking function is activated through a performance graph switchover: the threshold values for tripping the torque reduction are stored in memory in the two threshold value performance graphs 12 and 13 shown in FIG. 1. If the segment time gradient drops below the associated lower threshold value in the first threshold value performance graph 12, then an ignition angle intervention is carried out, by switching over from the first or basic ignition performance graph 10 to the second ignition performance graph 11. After the thus-effected triggering of the anti-bucking function, or in other words after the ignition time has been shifted toward "late", a switchover to the second threshold value performance graph 13, which has higher thresholds than the first performance graph 12, is carried out. After a freely determinable number of triggerings (for instance 2 to 3 triggerings), but at the latest after a predeterminable period of time (such as 750 ms) which is calculated beginning with the first triggering, a switchover back to the first performance graph 12 is effected.
If the rpm gradient receives the respective upper threshold value SO, then the anti-bucking function (which is also referred to below as the AR function) is turned off, or in other words a switchover back to the basic ignition performance graph 10 is made. The lower threshold value SU and the upper threshold value SO are dependent on the engine speed n. At higher engine speeds, the lower threshold value assumes higher values, and the upper threshold value assumes lower values, than at low engine speeds. This can be seen from FIG. 2, in which with increasing time the engine speed becomes greater, and on average the two threshold values SU and SO approach one another.
The adjustment of the ignition angle toward "late" upon activation of the anti-bucking function is performed with a limitation in the range of change (for instance, to 6° of ignition angle per segment), by means of which discontinuities in the ignition angle are damped.
Once the aforementioned number of triggerings has been accomplished, or in other words the predetermined number of engine interventions with torque reduction have been carried out, or once a predetermined maximum period of time T MAX has elapsed, an idle time TOTZ -- AR begins, during which the AR function remains deactivated. However, if the throttle value gradient, or in other words the rate of change of the throttle valve actuation, exceeds a predetermined threshold value during the idle time, then the idle time is discontinued. The AR function can then be tripped again.
The command ignition angle resulting from the anti-bucking function, in accordance with the ignition performance graph 11, is compared with the command ignition angles that result from other ignition angle corrections at partial load or full load, and whichever ignition angle is later is then established. The transition in the "early" direction to the basic ignition angle once the torque reduction has been ended is always performed with a limitation in the rate of change of the ignition angle.
The torque reduction can also be tripped by a detection of acceleration enrichment. The threshold values for tripping the ignition intervention are stored in memory in a performance graph, such as the threshold value performance graph 12. Once the leading edge of a signal that indicates an acceleration enrichment operating state BA has been detected, the anti-bucking function is activated for a period of time T -- MAX -- BA. If the segment time gradient drops below the corresponding threshold value of the performance graph during this period of time, then a predeterminable number of triggerings or trippings of the ignition intervention takes place. Upon the first triggering, a second, likewise predetermined period of time begins. After one of these periods of time, or the predetermined number of triggerings, has elapsed, the AR function is inactivated until such time as a leading edge of the signal "BA" is again detected.
The torque reduction is also discontinued if the operating states known as overrunning reduction or overrunning shutoff are active.
With higher and higher gears, the frequency of bucking vibrations rises. Therefore, by means of a gear detection that is carried out from the engine speed and from the vehicle speed signal by means of a microprocessor 14 contained in the engine control 2, the following variables are adapted to the various gears. As the gear number increases:
the threshold values SU for tripping the AR function become higher, and the threshold values SO for ending the function are made lower;
the ignition angle rate of change limitations is increased, and the number of segments for delaying the change in ignition angle is reduced;
the maximum intervention time T -- MAX is shortened.
FIG. 3 shows the dependency of the lower threshold values or starting thresholds SU1 (SU from performance graph 12) and SU2 (SU from performance graph 13) for the AR function on the engine speed.
FIGS. 4a and 4b show a flowchart of the program that the microprocessor 14 of the engine control 2 goes through in executing the anti-bucking function:
After a starting step 20 in FIG. 4a, it is ascertained in an interrogation step 21 whether or not the aforementioned conditions for the AR function are met. If not, a jump back to the start is made. If they are, then in an interrogation step 22 it is ascertained whether or not the engine speed is below a predetermined threshold, of 1900 rpm, for instance. If so, the segment time gradient is calculated in a block 23 from two successive segment times. If not, it is calculated in a block 24 from two successive revolution times.
In a question step 25 it is ascertained whether or not the number of triggerings equals 1. If so, then in a question step 26 it is ascertained whether the segment time gradient is less than the lower threshold value SU1 from the first threshold value performance graph 12. In not, then in an interrogation step 27 it is ascertained whether or not it is less than the lower threshold value SU2 from the performance graph 13. If the result of the respective interrogation is negative, a jump is made back to the start. If it is positive, then in both cases in a step 28 the start of a time counter for the maximum period of time T -- MAX takes place.
In a program step 29, an ignition angle intervention with rate of change limitation is carried out and this leads to a reduction in the engine torque.
In an interrogation step 30, it is ascertained whether or not the segment time gradient is higher than the upper threshold value SO. If so, then in a step 31 seen in FIG. 4b the ignition angle intervention is ended. If not, then in an interrogation step 32 it is ascertained whether or not the maximum period of time T -- MAX has elapsed. If not, a jump is made back to before the step 29. If so, then the ignition angle intervention is ended in the step 31.
In a step 33, the number of triggerings is raised by 1. In a question step 34 it is ascertained whether or not the predetermined maximum number of triggerings of the AR function has been exceeded. If not, a jump back to the start is made. If so, then in a step 35 the number of triggerings is set equal to one. In a step 36, a time counter for the idle time TOTZ -- AR is started.
In a question block 37 it is ascertained whether or not the maximum idle time has been exceeded. If so, a jump is made back to the start. If not, it is ascertained in an interrogation block 38 whether or not the throttle value gradient exceeds a predetermined value. If not, a jump is made back to before the step 37. If so, a jump is made back to the start. This ends the run through the program.
In the above-described exemplary embodiments, the information about the engine speed has always been evaluated by way of the segment time gradient. Instead of using the segment time gradients TN-GRD, the anti-bucking system can also be controlled and carried out by using the engine speed gradient dn/dt. However, in that case the upper and lower threshold values must be transposed. | A method and an engine control for suppressing vibration in the drive train of a motor vehicle include detecting a variable being dependent on a speed of an engine, deriving and evaluating a gradient from the variable, reducing a torque of the engine by varying an ignition angle if impermissible vibration is detected, and controlling the torque reduction as a function of an upper and a lower threshold value for the gradient. An ignition intervention is carried out for reducing the engine torque if the gradient is below the lower threshold. The ignition intervention is cancelled if the gradient exceeds the upper threshold value. First lower threshold values are stored in a first performance graph, and second higher threshold values are stored in a second performance graph to which a switchover is made after a first tripping of an anti-bucking function. | 5 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to refrigeration units, including refrigerator appliances, refrigerating systems, and cold storage units.
[0003] 2. Background
[0004] Many earlier refrigeration systems have utilized refrigerants that are potentially harmful when released to the environment. Certain refrigerants are desirable because they present higher operating efficiencies when used in conventional systems, although they may pose adverse environmental risks. Some efforts have been made to replace such harmful gaseous fluids with alternative fluids that are less harmful to the environment. However, such systems have suffered from various limitations and relatively low heat transfer efficiencies.
[0005] In addition, earlier cooling and heating systems have included conventional heat exchange manifolds, piping and pumping systems for refrigerants. Some of the earlier systems have also incorporated thermoelectric modules for specifically defined cooling or heating functions. By way of example, the following US Patents described examples of such earlier systems: U.S. Pat. No. 6,354,086 to Inoue et al., U.S. Pat. No. 5,232,516 to Hed, U.S. Pat. No. 5,269,146 to Kerner, U.S. Pat. No. 5,540,567 to Schirpke et al., U.S. Pat. No. 5,653,111 to Attey et al., and U.S. Pat. No. 5,675,973 to Dong. The foregoing examples describe conventional fluid pumping and piping systems for transportation of fluid within the heat transfer or cooling systems described in those patents.
[0006] Some of the earlier systems have attempted to improve the efficiency of heat exchange by incorporating complex fluid agitators. U.S. Pat. No. 6,354,086 to Inoue et al. is an example of an earlier patent in which such agitators are described. U.S. Pat. No. 5,269,146 describes a closed system heating and cooling system for thermally insulated containers such as portable refrigerated chests, heated bottles and serving carts for hotels and restaurants. Thermally conductive fluid is circulated through a closed loop circulating system. The heated or cooled fluid is passed through an air core heat exchanger for heat exchange with surrounding ambient air. The patent describes that the fluid is pumped at high speeds through the closed system to promote efficient heat transfer.
[0007] Korean patent 2000-54406 is an example of an earlier cooling system using a thermoelectric module and conventional heat transfer arrangement. Another example of an earlier heat transfer system employing a heat transfer pipe without thermoelectric module components, is described in Korean patent number 190443. All of these earlier systems include conventional piping and circulation systems for refrigerants or other fluids. Many of these systems are prone to leakage and system malfunctions associated with mechanical problems, such as compressor failures.
[0008] These earlier systems have not addressed the advantages of providing refrigeration systems having the improved efficiencies associated with the use of natural forces and inherent fluid flow characteristics of the capillary flow systems described below.
SUMMARY OF THE INVENTION
[0009] The invention includes a refrigeration apparatus. In one aspect, the manifold defines an inner chamber containing an effective amount of a selected refrigerant. The inner chamber comprises an elongated first chamber, an elongated second chamber, and a plurality of heat pipes which define capillary channels in fluid communication between the first and second chambers. A selected number of thermoelectric modules are used to cool the refrigerant contained within the manifold. Preferably, the thermoelectric modules are positioned in cooling contact with a thermal transfer area defined by the manifold. A blower is provided to remove excess heat from the heating faces of the thermoelectric modules.
[0010] Thermoelectric modules are also known in the art as Peltier devices. Earlier examples of Peltier devices are generally wafer-like structures that produce heat and cooling effects upon application of electric current.
[0011] In another aspect, a refrigeration device is provided. In this example, the refrigeration device includes a housing. The housing defines one or more interior spaces. The interior spaces are in cooling, thermal communication with one or more manifolds. Each manifold defines an interior chamber containing an effective amount of a selected refrigerant. The inner chamber of the manifold comprises:
[0012] a first cylinder, a second cylinder, and a plurality of capillary channels defined by the heat pipes. The channels establish fluid communication between the first and second cylinders. A plurality of thermoelectric modules are arranged so that their cooling faces thermally communicate with the manifold.
[0013] In this example, one or more blowers are provided to force an air stream to cool the heating faces of the thermoelectric modules.
[0014] By way of example, in another aspect, the present invention includes a heat transfer manifold used with arranged banks of thermoelectric modules. The apparatus may be employed in association with refrigeration systems, including appliances, cold storage units and other cooling systems. The manifold is particularly useful in those instances where it is desirable to avoid the use of conventional refrigerants such as freon and other potentially harmful refrigerants.
[0015] Examples of preferred refrigerants are described.
[0016] The manifold is typically positioned in a generally vertical orientation when the manifold is in operation, as described in more detail further below. In one aspect, the manifold comprises an upper cooling pipe that is in parallel alignment with a vertically opposed feeder pipe or head pipe. The head pipe or cooling pipe may be provided with a fluid opening to input thermally conductive fluid. In some instances, the fluid opening may be resealable so that refrigerant may be re-charged into the manifold. A plurality of generally planar heat pipes are positioned between the cooling pipe and the head pipe. In some instances, it is desirable to position the heat pipes so that their planar faces are parallel to the longitudinal axes of the cooling pipe and head pipe. In this embodiment, the heat pipes are coplanar and positioned so that their planar faces are aligned along the lengths of the cooling pipe and head pipe.
[0017] As noted above, a refrigerant is provided within the closed fluid reservoir of the manifold. Heat exchange occurs through the operation of the thermoelectric modules and the repeated evaporation and condensation of the refrigerant within the fluid reservoir of the manifold.
[0018] Preferably, each heat pipe is generally elongated and flat. The heat pipe is internally divided into capillary channels running along the length of the heat pipe. Preferably, the channels form a single layer of capillaries running along the length of the heat pipe. Each capillary channel extends from one end of the heat pipe to the other end of the heat pipe. Each capillary channel provides fluid communication between the cooling pipe and the opposed head pipe.
[0019] The manifold component may be used in combination with a plurality of thermoelectric modules that have been aligned in planar arrays so that all heating faces of the modules are along one side of the array, and the cooling faces of the modules are along the opposite side of the array. The row of modules is positioned adjacent to the manifold to establish cooling, thermal communication between the cooling faces of the modules and the manifold.
[0020] In some instances, the row of thermoelectric modules may be placed in contact with a heat transfer surface defined by either the cooling pipe, head pipe, or a coplanar array of heat pipes. In the preferred embodiment, the cooling faces of the thermoelectric modules are placed in thermal communication with an elongated heat transfer surface defined by the cooling pipe.
[0021] In one aspect of the invention, the capillary channels in a heat pipe are generally rectangular tubes defined by the interior walls of the heat pipe. Preferably, the interior walls extend orthogonally from one face of the heat pipe to the opposing face of the heat pipe. However, the capillaries may be manufactured to have other cross-sectional configurations that are not necessarily square or rectangular in shape. The relative size of the capillaries will vary according to the design requirements and characteristics of the desired cooling system. The diameter of the capillaries may be adjusted to accommodate the particular flow characteristics of a specific fluid selected for use in the system. Design characteristics, including the optimal diameters for the capillaries may be adapted to account for differences in fluid flow, heat transfer characteristics, surface tension, and other physical properties exhibited by different refrigerants.
[0022] In a preferred embodiment, the manifold will be positioned for operation so that the capillaries will extend in a generally vertical direction. The fluid flow and heat transfer characteristics within the capillaries will be enhanced by this vertical arrangement. It is preferred that the rows of modules be positioned near the top of the manifold to enhance generally downward thermal and fluid flow tendencies within the capillaries.
[0023] In a preferred embodiment, the capillaries are arranged in a single layer of capillaries within the outer walls of the heat pipes. In other instances, multiple layers of capillaries may be provided within the outer walls of a heat pipe, although in many cases, such an arrangement may not be preferred.
[0024] The manifold component is preferably made of a relatively strong, resilient, and thermally conductive material and most preferably, a metal which is not susceptible to excessive corrosion. Aluminum is a particularly useful material of construction for many applications of the present invention. Of course, persons skilled in the art will understand that other materials, including other metals, alloys, or non metallic materials may be desirable for use in the particular conditions and circumstances under consideration.
[0025] Preferably, the fluid within the reservoir is filled until the liquid phase occupies about 40% to 70% of the volume of the reservoir. The vapor phase will occupy between about 30% and 60% of the volume of the reservoir. In a preferred cooling application, a suitable coolant will be filled until about 60%-70% of the reservoir volume is filled with the liquid phase, and 30%-40% of that volume is filled with the vapor phase.
[0026] Embodiments of the inventions may be made of modular components, unlike many conventional cooling system designs. For example, the cooling manifolds are self contained units, and once they are disconnected from a power source, and optional control unit, may be extracted from the enclosing structure. The removed manifold or other modular components may be repaired or replaced with relative ease. Many conventional systems have complicated piping and pumping systems, expensive components and present various obstacles to repair or replacement of the refrigerating cores. Conventional pumps, compressors, and other system components are often expensive. The invention includes embodiments which permit system designs avoiding the use of many expense conventional system components.
[0027] Other embodiments of the invention include fixed cold storage compartments provided in buildings and other structures. By way of example, modular manifold arrangements may be provided for installation along one or more interior walls of an insulated cold storage compartment of a building. In other embodiments, refrigerator units may be manufactured for installation with storage compartments and vehicles, including truck trailers, shipping containers and other like structures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] In the following description, the invention is further explained in connection with a preferred embodiment making reference to the drawings in which:
[0029] [0029]FIG. 1 is a perspective, exploded representation of a refrigerator appliance in which the major components are depicted in a disassembled view.
[0030] [0030]FIG. 2 is a perspective representation of a cooling manifold wherein the major comments are depicted in an exploded view.
[0031] [0031]FIG. 3 is a perspective depiction of an enlarged partial exploded view of a heat pipes and cooling pipe of the manifold depicted in FIG. 2.
[0032] [0032]FIG. 4 is an enlarged partial view of two adjacent heat pipes depicted in FIG. 3.
[0033] [0033]FIG. 5 is an enlarged partial sectional view of several adjacent heat pipes of the manifold and the head pipe portion the manifold shown in FIG. 2.
[0034] [0034]FIG. 6 is a perspective depiction of a partial section of an upper portion of the manifold shown in FIG. 2.
[0035] [0035]FIG. 7 is a perspective depiction of a partial section of an upper portion of the manifold shown in FIG. 2, further depicting an array of cooling fins adjacent the upper portion of the manifold.
[0036] [0036]FIG. 8 is a perspective depiction of the air cooling components of the manifold shown in FIG. 2, depicted in exploded view.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0037] [0037]FIG. 1 shows a refrigerator appliance as one embodiment of the present invention in an exploded view, featuring several major components of the refrigerator. Outer doors 100 enclose two interior compartments defined by a unitary shell 200 . A cooling manifold assembly 300 includes two manifold assemblies which surround opposing side walls of shell 200 . An outer housing 500 is provided to receive the other major components of the refrigerator appliance. Upper hinge mounts 510 and lower hinge mounts 520 are used to secure front doors 100 to the housing 500 .
[0038] In FIG. 1, one of the two manifold assemblies is depicted in exploded view. The manifold assembly 300 includes two opposing banks of heat pipes 320 . The two banks of heat pipes are depicted in a generally, vertical arrangement. The two banks of heat pipes, when installed in the appliance, will be in thermal communication with a corresponding internal storage compartment of the appliance. The two banks of heat pipes are preferably parallel to the interior walls of the storage compartment. Each bank of heat pipes 320 is attached for fluid communication with a corresponding head pipe 330 . Refrigerant is charged within the interior chamber of the manifold. The refrigerant circulates without the use of a refrigerant pump or compressor. Each bank of heat pipes presents a substantial heat transfer area, due in part to the elongated, flat surfaces of the heat pipes. Similarly, the internal capillary structure of the heat pipes further enhances the effective heat transfer area between the refrigerant and the interior space of the storage compartment. The substantial heat transfer area enhances the overall efficiency of the refrigeration system.
[0039] An upper cooling assembly 310 comprises a linear array of cooling fans, positioned in thermal communication above an array of thermoelectric modules 315 and an underlying cooling pipe 317 . FIG. 3 shows an enlarged partial view of the connection established between upper ends of heat pipes 320 and corresponding fluid ports leading to the interior chamber defined by cooling pipe 317 . Cooling pipe 317 , in this embodiment, provides a common chamber for circulating refrigerant contained within the manifold. The heat pipes of both opposing banks of heat pipes are in common, fluid communication with the interior chamber of the cooling pipe 317 . Refrigerant contained within the manifold communicates between the interior space defined by the cooling pipe 317 and the head pipes 330 . Each head pipe 330 defines an interior space for fluid communication between the opposite (lower) ends of the respective banks of heat pipes 320 . Refrigerant contained within the manifold communicates between head pipes 330 and the cooling pipe 317 via the capillary channels defined in each heat pipe. FIG. 4 shows a pair of adjacent ends of heat pipes 320 , arranged in a common plane, with each heat pipe having a single layer of capillary channels extending in parallel along the length of the corresponding heat pipe. The capillary channels in the heat pipes allow refrigerant to communicate between head pipes 330 and the common cooling pipe 317 . With reference with FIG. 5, downwardly oriented arrows represent chilled refrigerant traveling downwardly along the various capillary channels. Chilled refrigerant, travelling in plugs of condensed refrigerant liquid, descends along the capillary channels. At the same time, portions of the refrigerant will evaporate during operation of the manifold causing vapor plugs of the refrigerant to ascend through various capillary channels of the heat pipes (as represented by the upwardly pointing arrow). Evaporated refrigerant enters into the cooling pipe 317 where the refrigerant will be chilled by the cooling operation of an array of thermoelectric modules 315 .
[0040] With reference to FIGS. 6, 7, and 8 , a linear array of thermoelectric modules 315 contacts a heat transfer surface defined by cooling pipe 317 . The thermoelectric modules 315 are all arranged so that their respective cooling faces are in contact with cooling pipe 317 . Consequently, the heating faces of the thermoelectric modules 315 face outwardly away from the cooling pipe 317 . The heating faces of the thermoelectric modules 315 are in thermal communication with an upwardly projecting bank of cooling fins 314 . Cooling fins 314 are arranged in parallel so that adjacent fins within the arrangement define air flow channels for air forced through the channels by a linear array of fans 312 . The fans force air across the cooling fins to remove excess heat generated by the heating faces of the thermoelectric modules 315 . The fans are operated, preferably, through a control unit (not shown) set to activate the fans during operation of the thermoelectric modules 315 . Similarly, the control panel (not shown) may be set to actively operate the thermoelectric modules to maintain a set, desirable temperature for the internal storage compartment of the refrigerator appliance.
[0041] In FIG. 8, a detailed representation of the air cooling assembly is shown. As noted above, cooling pipe 317 defines a contact surface for the cooling faces of the array of thermoelectric module 315 . Cooling pipe 317 includes a capped port 318 that may be used to charge and refill the manifold with a selected refrigerant. The cooling assembly includes a protective gasket 316 which frames an array of thermoelectric modules 315 . The gasket 316 is positioned between the lower surface of the cooling fin array 314 and the heat transfer surface defined by the cooling pipe 317 . Gasket 316 protects the thermoelectric modules against accidental damage due to over tightening of the fasteners used to assemble the various components of the air cooling assembly. In addition, the gasket 316 may be provided with insulative qualities to inhibit undesirable heat transfer activity at the interface between the cooling fin array 314 and cooling pipe 317 . The cooling pipe 317 , the gasket 316 , and the base of the cooling fin array 314 define co-axial holes for receiving bolts 311 used to secure the vertically stacked components of the cooling assembly. By way of example, bolt 311 extends through a co-axial bore defined by a fan housing in fan array 312 , a bore defined by a support collar 313 , the base of cooling fin array 314 , a bore defined by gasket 316 , and a bore defined by cooling pipe 317 . The bolts 311 are secured within the assembly by nuts (not shown).
[0042] In this embodiment, air is inducted into the air flow channels formed between opposing pairs of cooling fins 314 . The flowing air is warmed upon contact with the cooling fins 314 and is exhausted near the upper end of the outer housing of the refrigerator appliance. The heating faces of thermoelectric modules are thereby cooled to prevent overheating during operation of the refrigerator appliance.
[0043] In this illustrated embodiment, the interior compartment of the appliance includes a freezer compartment and cooling compartment. The freezer and cooling compartments are arranged side by side. Two banks of heat pipes 320 i.e. one bank from the two depicted manifolds, extend vertically through the gap formed between the freezer and chilling compartments. The first manifold, used to chill the cooling compartment, may be operated by a control panel which is separate and distinct from a second control panel used to operate the freezer compartment. The two control panels may be operated and wired independently of each other.
[0044] In the preferred embodiment, the cooling fans are arranged in two linear arrays, in which one array of fans is positioned above the cooling manifold for the freezer compartment and a second fan array is positioned above the manifold used to cool the cooling compartment. The two cooling fan arrays are controlled independently in the preferred embodiment.
[0045] Although a refrigerator appliance is depicted in the preferred embodiment, other embodiments will be apparent. For example, a portable cooling chest may be provided in which a manifold is used for cooling one or more interior walls of the chest. The overall size, configuration and power demands of the manifold are in part, depend upon the surface area, volume, and insulative qualities of the portable cooling chest. (A cooling chest may be designed for optimal operation so that the chest is positioned, in its normal orientation, so that the heat pipes in the manifold define capillary channels orientated in a generally vertical direction.
[0046] In a portable cooling chest, a portable power source, including, a storage battery or portable generator may be provided to power a pre-selected number of thermoelectric modules to cool the internal compartment of the chest. One or more cooling fans may be provided, as required. A cooling chest may also be provided with adapters to convert AC power to a DC power supply for the thermoelectric modules. Similarly, adapters may be provided to connect with power outlets in vehicles for powering accessories. Other power source arrangements may also be provided.
[0047] The thermoelectric modules are supplied with electric current from a suitable power source which is not shown. The power source is typically a DC power unit selected with the appropriate operational requirements for the thermoelectric modules and heat transfer requirements for the particular application.
[0048] A wide range of refrigerants may be used in the manifold of the invention, including conventional refrigerants. However, the following are two examples of preferred refrigerants, identified as OS-12b™ and OS-12a™, which are believed to offer certain environmental advantages, as compared to selected conventional refrigerants.
TABLE 1 1) OS-12b ™ Classification OS-12b HCFC-22 HFC-1 Molecular mass 113.38 120.93 102.03 Boiling temperature (C.) −26.59 −29.8 −26.5 Heat of vaporization at 0 C. 248.3 149.8 198.7 (KJ/Kg) Stabilities Thermal Stable Stable Stable Chemical Stable Stable Stable Erosive No No No Flammability (LFL & UFL) None None None Autoignition temperature (C.) None None None Toxicity No No No O.D.P. (Ozone depletion poten- 0 1 0 tial) G.W.P. (Global warming potential <3 8,100 1,300 in relation to CO2 with 100 years integration time) Lubricant Mineral Mineral Ester 2) OS-12a ™ Classification OS-12a HCFC-22 HFC-1 Molecular mass 57.9 120.93 102.03 Boiling temperature (C) −34.5 −29.8 −26.5 Heat of vaporization at 0 C. 367.0 149.8 198.7 (KJ/Kg) Stabilities Thermal Stable Stable Stable Chemical Stable Stable Stable Erosive No No No Flammability (LFL & UFL) 3.7˜9.5% None None Autoignition temperature (C.) 540 None None Toxicity No No No O.D.P. (Ozone depletion potential) 0 1 0 G.W.P. (Global warming potential 3 8,100 1,300 in relation to CO2 with 100 years integration time) Lubricant Mineral/Ester Mineral Ester
[0049] The above Table 1 is reproduced from information published by Technochem Co., Ltd. (http://www.technochem.com), Republic of Korea.
[0050] ™—Trade-mark of Technochem Co., Ltd., Republic of Korea
[0051] Of course, other refrigerants may be selected for various reasons. After a suitable refrigerant is selected, it is preferable to evacuate entrapped air from the interior of the manifold, during manufacture of the manifold. For example, the air may be evacuated through an access port. In the preferred embodiment, substantially all of the entrapped air will be removed and thereafter, the refrigerant will be charged into the interior of the reservoir of the manifold.
[0052] Certain other refrigerants will also be preferred for certain applications. For example, conventional refrigerants such as R-142, R-141B and others may be used in cooling applications with a suitably adapted heat exchange manifold.
[0053] With respect to the heat pipe design, it is believed that capillaries with cross-sectional diameters of about 4 mm in diameter were particularly efficient in refrigeration applications. In some instances, it may be desirable to use capillaries with smaller effective diameters. Capillary tubes that are generally rectangular when viewed in cross section may have dimensions of 1 mm×1.4 mm or lower. In other instances, the capillaries may have cross-sectional dimensions of about 0.5 mm×0.6 mm. Of course, other sizes of capillaries may be selected, based on various design considerations.
[0054] However, the optimal size of the capillaries may vary according to the physical properties of the thermally conductive fluid selected for use in a particular heat exchange system. For example, surface tension, fluid viscosity and other factors may affect the optimal effective diameter of the capillaries in a particular system. A number of factors may affect fluid performance and thus affect the optimal and maximum diameters of the capillaries to be provided in the refrigeration system.
[0055] It will be appreciated that refrigerants will tend to flow within the internal channels of the manifold due in part to cooling of the fluid and the capillary action exerted on the fluid within the capillaries of the manifold. One of the advantages of the invention is that it is unnecessary to provide a circulating pump to circulate the refrigerant within the interior chamber of the manifold. Although there may be instances where a circulating pump may be added, such a pump would not be necessary to circulate the refrigerant provided within the manifold.
[0056] The present invention has been described with reference to preferred embodiments. However, other embodiments of the invention, and variations and modifications thereof will be apparent to those persons having ordinary skill in the art. It is intended that those other embodiments, variations and modifications thereof, will be included within the scope of the present invention as claimed within the appended claims. | A refrigerator includes a housing that defines an enclosable storage space. The refrigerator includes a closed manifold which defines a chamber to contain refrigerant. The chamber is made up of three parts, a cooling pipe, a head pipe, and one or more heat pipes to communicate fluid between the cooling and head pipes. The heat pipes are flat, elongated, and are divided internally to form capillary channels to permit flow of refrigerant between the cooling and head pipes. An array of thermoelectric modules contacts a surface of the manifold to chill refrigerant within the manifold. A pump or compressor is not required to circulate the refrigerant within the system. A blower forces an air stream to cool the heating faces of the thermoelectric modules. A control unit may be used to maintain the operating temperature of the refrigerator. A refrigerator may be portable, with a portable power source or adapters. The manifold design is useful for modular refrigerator appliance designs. The manifold is also useful in other refrigerating systems, cold storage units and portable devices. | 5 |
This is a divisional application of U.S. Ser. No. 07/585,758 filed Sep. 20, 1990, now U.S. Pat. No. 5,045,550.
BACKGROUND OF THE INVENTION
The present invention relates to novel substituted tetrahydropyridines and derivatives thereof useful as pharmaceutical agents, to methods for their production, to pharmaceutical compositions which include these compounds and a pharmaceutically acceptable carrier, and to pharmaceutical methods of treatment. The novel compounds of the present invention are central nervous system agents. More particularly, the novel compounds of the present invention are dopaminergic agents.
A series of pyridine derivatives of the formula ##STR1## wherein R 1 and R 2 are independently each phenyl or 2-or 3-thienyl radicals which are unsubstituted or monosubstituted or disubstituted by alkyl, alkoxy, F, Cl, Br, OH, and/or CF 3 and n is 1, 2, or 3, and the alkyl and alkoxy groups each have 1-4 C atoms and salts thereof having suppressant actions on the central nervous system is disclosed in U.S. Pat. No. 4,665,187.
However, the compounds disclosed in the aforementioned references do not disclose or suggest the combination of structural variations of the compounds of the present invention described hereinafter.
SUMMARY OF THE INVENTION
Accordingly, the present invention is a compound of Formula I ##STR2## wherein R is ##STR3## X is ##STR4## or --CH 2 --;
n is an integer of 2 to 4;
R 1 is aryl, 2- or 3-1H-indolyl, or 2- or -1H-indolyl substituted by lower alkyl, lower alkoxy, or halogen, 2-, 3-, or 4-pyridinyl, or 2-, 3-, or -pyridinyl substituted by lower alkyl, lower alkoxy, or halogen, 2-, 4-, or 5-pyrimidinyl, or 2-, 4-, or -pyrimidinyl substituted by lower alkyl, lower alkoxy, or halogen, 2-pyrazinyl or 2-pyrazinyl substituted by lower alkyl, lower alkoxy, or halogen, 2- or 3-thienyl, or 2- or 3-thienyl substituted by lower alkyl or halogen, 2- or 3-furanyl, or 2- or 3-furanyl substituted by lower alkyl or halogen, 2-, 4-, or 5-thiazolyl, or 2-, 4-, or 5-thiazolyl substituted by lower alkyl or halogen; or a pharmaceutically acceptable acid addition salt thereof.
As dopaminergic agents, the compounds of Formula I are useful as antipsychotic agents for treating psychoses such as schizophrenia. They are also useful as antihypertensives and for the treatment of disorders which respond to dopaminergic activation. Thus, other embodiments of the present invention include the treatment, by a compound of Formula I, of hyperprolactinaemia-related conditions, such as galactorrhea, amenorrhea, menstrual disorders and sexual dysfunction, and several central nervous system disorders such as Parkinson's disease, Huntington's chorea, and depression.
A still further embodiment of the present invention is a pharmaceutical composition for administering an effective amount of a compound of Formula I in unit dosage form in the treatment methods mentioned above.
Finally, the present invention is directed to methods for production of a compound of Formula I.
DETAILED DESCRIPTION OF THE INVENTION
In the compounds of Formula I, the term "lower alkyl" means a straight or branched hydrocarbon radical having from one to six carbon atoms and includes, for example, methyl, ethyl, n-propyl, isopropyl, n-butyl, sec-butyl, isobutyl, tert-butyl, n-pentyl, n-hexyl, and the like.
The term "aryl" means an aromatic radical which is a phenyl group or phenyl group substituted by one to four substituents selected from lower alkyl, lower alkoxy, lower thioalkoxy, halogen or trifluoromethyl such as, for example, benzyl, phenethyl, and the like.
"Lower alkoxy" and "thioalkoxy" are 0-alkyl or S-alkyl of from one to six carbon atoms as defined above for "lower alkyl."
"Halogen" is fluorine, chlorine, bromine, or iodine.
"Alkali metal" is a metal in Group IA of the periodic table and includes, for example, lithium, sodium, potassium, and the like.
"Alkaline-earth metal" is a metal in Group IIA of the periodic table and includes, for example, calcium, barium, strontium, magnesium, and the like.
"Noble metal" is platinum, palladium, rhodium, ruthenium, and the like.
Pharmaceutically acceptable acid addition salts of the compounds of Formula I include salts derived from nontoxic inorganic acids, such as hydrochloric, nitric, phosphoric, sulfuric, hydrobromic, hydriodic, phosphorous, and the like, as well as the salts derived from nontoxic organic acids, such as aliphatic mono- and dicarboxylic acids, phenyl-substituted alkanoic acids, hydroxy alkanoic acids, alkanedioic acids, aromatic acids, aliphatic and aromatic sulfonic acids, etc. Such salts thus include sulfate, pyrosulfate, bisulfate, sulfite, bisulfite, nitrate, phosphate, monohydrogenphosphate, dihydrogenphosphate, metaphosphate, pyrophosphate, chloride, bromide, iodide, acetate, propionate, caprylate, isobutyrate, oxalate, malonate, succinate, suberate, sebacate, fumarate, maleate, mandelate, benzoate, chlorobenzoate, methylbenzoate, dinitrobenzoate, phthalate, benzenesulfonate, toluenesulfonate, phenylacetate, citrate, lactate, maleate, tartrate, methanesulfonate, and the like. Also contemplated are salts of amino acids such as arginate and the like and gluconate, galacturonate (see, for example, Berge, S. M., et al, "Pharmaceutical Salts," Journal Pharmaceutical Science, Vol. 66. pages 1-19 (1977)).
The acid addition salts of said basic compounds are prepared by contacting the free base form with a sufficient amount of the desired acid to produce the salt in the conventional manner. The free base form may be regenerated by contacting the salt form with a base and isolating the free base in the conventional manner. The free base forms differ from their respective salt forms somewhat in certain physical properties such as solubility in polar solvents, but otherwise the salts are equivalent to their respective free base for purposes of the present invention.
Certain of the compounds of the present invention can exist in unsolvated forms as well as solvated forms, including hydrated forms. In general, the solvated forms, including hydrated forms, are equivalent to unsolvated forms and are intended to be encompassed within the scope of the present invention.
A preferred compound of Formula I is one wherein R 1 is aryl, 2- or 3-1H-indolyl, or 2- or 3-1H-indolyl substituted by lower alkyl, lower alkoxy, or halogen, 2-, 3-, or 4 pyridinyl or 2-, 3-, or 4 pyridinyl substituted by lower alkyl, lower alkoxy, or halogen, 2-, 4-, or 5-pyrimidinyl or 2-, 4-, or 5-pyrimidinyl substituted by lower alkyl, lower alkoxy, or halogen, 2- or 3-thienyl or 2- or 3-thienyl substituted by lower alkyl or halogen.
Another preferred embodiment is a compound of Formula I wherein R 1 is aryl, 2- or 3-1H-indolyl, 2-, 3-, or 4-pyridinyl, 2-, 4-, or 5-pyrimidinyl, or 2- or 3-thienyl.
Particularly valuable are:
4-(3,6-Dihydro-4-phenyl-1(2H)-pyridinyl)-1-(3-pyridinyl)-1-butanone;
3-[4-(3,6-Dihydro-4-phenyl-1(2H)-pyridinyl)-butyl]pyridine;
3-[4-[3,6-Dihydro-4-(2-thienyl)-1(2H)-pyridinyl]-butyl]pyridine;
4-(3,6-Dihydro-4-phenyl-1(2H)-pyridinyl)-1-(4-pyridinyl)-1-butanone;
4-[4-(3,6-Dihydro-4-phenyl-1(2H)-pyridinyl)-butyl]pyridine;
2-[1,2,3,6-Tetrahydro-1-[4-(4-pyridinyl)butyl]-4-pyridinyl]pyridine;
3-[1,2,3,6-Tetrahydro-1-[4-(4-pyridinyl)butyl]-4-pyridinyl]-1H-indole;
4-[4-[3,6-Dihydro-4-(2-thienyl)-1(2H)-pyridinyl]-butyl]pyridine;
4-[3-(3,6-Dihydro-4-phenyl-1(2H)-pyridinyl)
4-[5-(3,6-Dihydro-4-phenyl pentyl]pyridine;
3-[4-(3,6-Dihydro-4-phenyl-1(2H)-pyridinyl)-butyl]quinoline;
3-[4-[3,6-Dihydro-4-(2-pyridinyl)-1(2H)-pyridinyl]butyl]quinoline;
2-[1,2,3,6-Tetrahydro-1-[4-(3-pyridinyl)butyl]-4-pyridinyl]pyridine;
4-(3,6-Dihydro-4-phenyl-1(2H)-pyridinyl)-1-(3-quinolinyl)-1-butanone;
3-[3-[3,6-Dihydro-4-(2-thienyl)-1(2H)-pyridinyl]propyl]quinoline;
3-[3-(3,6-Dihydro-4-phenyl-1(2H)-pyridinyl)-propyl]quinoline;
3-[5-[3,6-Dihydro-4-(2-thienyl)-1(2H)-pyridinyl]-butyl]quinoline;
3-[5-(3,6-Dihydro-4-phenyl-1(2H)-pyridinyl)-pentyl]quinoline; and
3-[5-(3,6-Dihydro-4-(2-thienyl)-1(2H)-pyridinyl]-pentyl]quinoline;
or a pharmaceutically acceptable acid addition salt thereof.
The compounds of Formula I are valuable dopaminergic agents. The tests employed indicate that compounds of Formula I possess dopaminergic activity. Thus, the compounds of Formula I were tested for their ability to inhibit locomotor activity in mice according to the assay described by J. R. McLean, et al, Pharmacology, Biochemistry and Behavior, Volume 8, pages 97-99 (1978); for their ability to inhibit [ 3 H]-spiroperidol binding in a receptor assay described by D. Grigoriadis and P. Seeman, Journal of Neurochemistry, Volume 44, pages 1925-1935 (1985); and for their ability to inhibit dopamine synthesis in rats according to the protocol described by J. R. Walters and R. H. Roth, Naunyn-Schmiedebero's Archives of Pharmacology, Volume 296, pages 5-14 (1976). The above test methods are incorporated herein by reference. The data in the table show the dopaminergic activity of representative compounds of Formula I.
TABLE 1__________________________________________________________________________Biological Activity of Compounds of Formula 1 Inhibition % Reversal of of Locomotor Brain Dopamine Inhibition of Activity Synthesis in [.sup.3 H]SpiroperidoExample in Mice Rats at BindingNumberCompound ED.sub.50, mg/kg, IP 10 mg/kg, IP IC.sub.50, μM__________________________________________________________________________9 4-(3,6-Dihydro-4-phenyl-1-(2H)- 1.1 50 --pyridinyl)-1-(3-pyridinyl)-1-butanone12 3-[4-(3,6-Dihydro-4-phenyl- 0.28 80 0.171(2H)-pyridinyl)butyl]pyridine8 3-[4-[3,6-Dihydro-4-(2-thienyl)- 0.66 71 1.291(2H)-pyridinyl]butyl]butyl]pyridine10 4-(3,6-Dihydro-4-phenyl-1(2H)- 1.0 57 0.408pyridinyl)-1-(4-pyridinyl)-1-butanone1 4-[4-(3,6-Dihydro-4-phenyl-1(2H)- 0.6 87 0.096pyridinyl)butyl]pyridine2 2-[1,2,3,6-Tetrahydro-1-[4-(4- 0.7 88 0.448pyridinyl)butyl]-4-pyridinyl]-pyridine3 3-[1,2,3,6-Tetrahydro-1-[4- 5.0 -- 0.398(4-pyridinyl)butyl]pyridinyl]-1H-indole4 4-[4-[3,6-Dihydro-4-(2-thienyl)- 1.2 -- 0.691(2H)-pyridinyl]butyl]pyridine5 4-[3-(3,6-Dihydro-4-phenyl-1-(2H)- 0.63 61 --pyridinyl)propyl]pyridine7 4-[5-(3,6-Dihydro-4-phenyl-1(2H)- 0.90 -- --pyridinyl)pentyl]pyridine13 3-[4-(3,6-Dihydro-4-phenyl-1-(2H)- 0.37 100 0.046pyridinyl)butyl]quinoline15 3-[4-[3,6-Dihydro-4-(2-pyridinyl)]- 0.14 -- --1-(2H)-pyridinyl]butyl]quinoline14 3-[5-[3,6-Dihydro-4-(2-thienyl)]-1- 1.50 -- --(2H)-pyridinyl]butyl]quinoline__________________________________________________________________________
A compound of Formula Ia ##STR5## wherein R is ##STR6## n is an integer of 2 to 4; R 1 is aryl, 2- or 3-1H-indolyl, or 2- or 3-1H indolyl substituted by lower alkyl, lower alkoxy, or halogen, 2-, 3-, or 4-pyridinyl, or 2-, 3-, or 4-pyridinyl substituted by lower alkyl, lower alkoxy, or halogen, 2-, 4-, or 5-pyrimidinyl, or 2-, 4-, or 5-pyrimidinyl substituted by lower alkyl, lower alkoxy, or halogen, 2-pyrazinyl or 2-pyrazinyl substituted by lower alkyl, lower alkoxy, or halogen, 2- or 3-thienyl, or 2- or 3-thienyl substituted by lower alkyl or halogen, 2- or 3-furanyl, or 2- or 3-furanyl substituted by lower alkyl or halogen, 2-, 4-, or 5-thiazolyl, or 2-, 4-, or 5 thiazolyl substituted by lower alkyl or halogen; or a pharmaceutically acceptable acid addition salt thereof may be prepared by reacting a compound of Formula Ib ##STR7## wherein R, R 1 , and n are as defined above with a reducing agent such as, for example, hydrazine, in the presence of an alkaline catalyst such as sodium hydroxide, potassium hydroxide, sodium methoxide, sodium ethoxide and the like, and a solvent such as, for example, ethylene glycol and the like, or amalgamated zinc and an acid such as, for example, concentrated hydrochloric acid and the like, optionally in the presence of a solvent such as, for example, ethanol, acetic acid, dioxane, toluene and the like, or treating a compound of Formula Ib with hydrogen in the presence of a catalyst such as a noble metal, for example, palladium on charcoal in the presence of a solvent such as, for example, ethanol and the like to give a compound of Formula Ia. Preferably, the reaction is carried out with hydrazine in the presence of potassium hydroxide and ethylene glycol.
Alternatively, a compound of Formula Ia may be prepared from a compound of Formula II ##STR8## wherein L is a halogen, or a leaving group such as, for example, methanesulfonyloxy, toluenesulfonyloxy and the like, and R and n are as defined above, and a compound of Formula III ##STR9## wherein R 1 is as defined above in the presence of a base such as, for example, an alkali metal or alkaline earth metal hydroxide, carbonate or bicarbonate, for example, sodium hydroxide, sodium carbonate, sodium bicarbonate, potassium hydroxide, potassium carbonate, potassium bicarbonate and the like in the presence of a solvent such as, for example, acetonitrile and the like to give a compound of Formula Ia. Preferably, the reaction is carried out in the presence of potassium bicarbonate and acetonitrile.
A compound of Formula Ib is prepared from a compound of Formula IV ##STR10## wherein R, N, and L are as defined above and a compound of Formula III using the methodology used to prepare a compound of Formula Ia from a compound of Formula II and a compound of Formula III.
Compounds of Formula II, Formula III, and Formula IV are either known or capable of being prepared by methods known in the art.
The compounds of the present invention can be prepared and administered in a wide variety of oral and parenteral dosage forms. It will be obvious to those skilled in the art that the following dosage forms may comprise as the active component, either a compound of Formula I or a corresponding pharmaceutically acceptable salt of a compound of Formula I.
For preparing pharmaceutical compositions from the compounds of the present invention, pharmaceutically acceptable carriers can be either solid or liquid. Solid form preparations include powders, tablets, pills, capsules, cachets, suppositories, and dispersible granules. A solid carrier can be one or more substances which may also act as diluents, flavoring agents, solubilizers, lubricants, suspending agents, binders, preservatives, tablet disintegrating agents, or an encapsulating material.
In powders, the carrier is a finely divided solid which is in a mixture with the finely divided active component.
In tablets, the active component is mixed with the carrier having the necessary binding properties in suitable proportions and compacted in the shape and size desired.
The powders and tablets preferably contain from five or ten to about seventy percent of the active compound. Suitable carriers are magnesium carbonate, magnesium stearate, talc, sugar, lactose, pectin, dextrin, starch, gelatin, tragacanth, methylcellulose, sodium carboxymethylcellulose, a low melting wax, cocoa butter, and the like. The term "preparation" is intended to include the formulation of the active compound with encapsulating material as a carrier providing a capsule in which the active component, with or without other carriers, is surrounded by a carrier, which is thus in association with it. Similarly, cachets and lozenges are included. Tablets, powders, capsules, pills, cachets, and lozenges can be used as solid dosage forms suitable for oral administration.
For preparing suppositories, a low melting wax, such as a mixture of fatty acid glycerides or cocoa butter, is first melted and the active component is dispersed homogeneously therein, as by stirring. The molten homogenous mixture is then poured into convenient sized molds, allowed to cool, and thereby to solidify.
Liquid form preparations include solutions, suspensions, and emulsions, for example, water or water propylene glycol solutions. For parenteral injection liquid preparations can be formulated in solution in aqueous polyethylene glycol solution.
Aqueous solutions suitable for oral use can be prepared by dissolving the active component in water and adding suitable colorants, flavors, stabilizing and thickening agents as desired.
Aqueous suspensions suitable for oral use can be made by dispersing the finely divided active component in water with viscous material, such as natural or synthetic gums, resins, methylcellulose, sodium carboxymethylcellulose, and other well-known suspending agents.
Also included are solid form preparations which are intended to be converted, shortly before use, to liquid form preparations for oral administration. Such liquid forms include solutions, suspensions, and emulsions. These preparations may contain, in addition to the active component, colorants, flavors, stabilizers, buffers, artificial and natural sweeteners, dispersants, thickeners, solubilizing agents, and the like.
The pharmaceutical preparation is preferably in unit dosage form. In such form the preparation is subdivided into unit doses containing appropriate quantities of the active component. The unit dosage form can be a packaged preparation, the package containing discrete quantities of preparation, such as packeted tablets, capsules, and powders in vials or ampoules. Also, the unit dosage form can be a capsule, tablet, cachet, or lozenge itself, or it can be the appropriate number of any of these in packaged form.
The quantity of active component in a unit dose preparation may be varied or adjusted foom 1 mg to 1000 mg preferably 10 mg to 100 mg according to the particular application and the potency of the active component. The composition can, if desired, also contain other compatible therapeutic agents.
In therapeutic use as antipsychotic agents, the compounds utilized in the pharmaceutical method of this invention are administered at the initial dosage of about 1 mg to about 50 mg per kilogram daily. A daily dose range of about 5 mg to about 25 mg per kilogram is preferred. The dosages, however, may be varied depending upon the requirements of the patient, the severity of the condition being treated, and the compound being employed. Determination of the proper dosage for a particular situation is within the skill of the art. Generally, treatment is initiated with smaller dosages which are less than the optimum dose of the compound. Thereafter, the dosage is increased by small increments until the optimum effect under the circumstances is reached. For convenience, the total daily dosage may be divided and administered in portions during the day, if desired.
The following nonlimiting examples illustrate the inventors' preferred methods for preparing the compounds of the invention.
EXAMPLE 1
4-(3,6-Dihydro-4-phenyl-1(2H)-pyridinyl)butyl]-pyridine
A mixture of 4-(4-pyridinyl)-1-butylchloride (Example A) (0 76 g, 4.47 mmol), 1,2,3,6-tetrahydro-4-phenylpyridine (0.796 g, 5.0 mmol), and potassium bicarbonat (1.0 g, 10 mmol) in 5 mL of acetonitrile are heated to reflux for 8 hours. The reaction is cooled to room temperature and the acetonitrile removed in vacuo. The residue is partitioned between 50 mL of water and 50 mL of chloroform. The aqueous layer is extracted again with 50 mL of chloroform and the combined organic extracts are dried over sodium sulfate and the solvent removed in vacuo. The resulting residue is chromatographed on silica gel (2% to 3% methanol, 0.1% ammonia, chloroform) to obtain 1.10 g of 4-[4-(3,6-dihydro-4-phenyl-1(2H)-pyridinyl)-butyl]pyridine as a white solid; mp 89`
In a process analogous to Example 1 using appropriate starting materials, the corresponding compounds of Formula I (Examples 2 to 8) are prepared as follows:
EXAMPLE 2
[1,2,3,6-Tetrahydro-1-[4-(4-pvridinyl)butyl]-4-pyridinyl]pyridine; mp 98°-99° C.
EXAMPLE 3
3-[1,2,3,6-Tetrahydro-1-[4-(4-pyridinyl)butyl]-4-pyridinyl]]-1H-indole; mp 177
EXAMPLE 4
4-[4-[3,6-Dihydro-4-(2-thienyl)-1(2H)-pvridinyl]-butyl]pyridine; mp 86°-87°
EXAMPLE 5
4-[3-(3,6-Dihydro-4-phenyl-1(2H)-pyridinvl)propyl]-pyridine; mp 166°-168° C.
EXAMPLE 6
2-[1,2,3,6-Tetrahydro-1-4-(3-pyridinyl)butyl}-4-pyridinyl]pyridine.
EXAMPLE 7
4-5-(3,6-Dihydro-4-phenyl-1(2H)-pyridinyl)butyl]-pyridine; mp 125°-126° C.
EXAMPLE 8
4-[3,6-Dihydro-4 (2-thienyl) 1{2H) pyridinyl]-butyl]pyridine; mp 44°-46° C.
EXAMPLE 9
4-(3,6-Dihydro-4-phenyl-1(2H)-pyridinyl)-1-(3-pyridinyl)-1-butanone
A solution of 4 chloro 3-(3-pyridinyl)-1-butanone (Example D) (17.8 g, 0.097 mol), 4-phenyl-1 2,3,6-tetrahydropyridine (44.7 g, 0.281 mol), an potassium iodide (0.8 g, 0.005 mol) are heated on a steam bath for 15 minutes. The residue is taken up in chloroform (60 mL) and the precipitate is filtered. The filtrate is evaporated in vacuo and purified by column chromatography (silica gel, 2% methanol/dichloromethane). The major product is crystallized from diethyl ether to give 4.5 g of -(3,6-dihydro-4-phenyl-1(2H)-pyridinyl)-1-(3-pyridinyl)-1-butanone as a solid; mp 64°-66° C.
In a process analogous to Example 9 using appropriate starting materials the corresponding compounds of Formula I (Examples 10 to 12) are prepared as follows:
EXAMPLE 10
4-(3,6-Dihydro-4-phenyl-1(2H)-pyridinyl)-1-(4-pyridinyl) 1-butanone; mp 97°-98° C.
EXAMPLE 11
4-(3,6-Dihydro-4-phenyl-1(2H)-pyridinyl)-1-(3-quinolinyl)-1-butanone; mp 106°-107° C.
EXAMPLE 12
3-4-(3,6-Dihydro-4-phenyl-1(2H)-pyridinyl)butyl]-pyridine; mp 45°-46° C.
EXAMPLE 13
3-[4-(3,6-Dihydro-4-phenyl-1(2H)-pyridinyl)butyl]-quinoline
A solution of 4-(3-quinolinyl)butan-1-ol (Example E) (2.0 g, 0.01 mol), N,N diisopropyl-ethylamine (3.5 mL, 0.02 mol) and a catalytic amount of 4-dimethylaminopyridine is cooled to 0° C. and methanesulfonyl chloride (0.8 mL, 0.0105 mol) is added dropwise. The solution is stirred at 0° C. for 18 hours, and concentrated under reduced pressure. The residue is taken up in dimethylformamide (20 mL), and to this solution is added 4-phenyl-1,2,3,6-tetrahydropyridine (2.41 g, 0.015 mol) and sodium bicarbonate (3.4 g, 0.04 mol). The mixture is heated at 40° C. for 5 hours and the solvent removed under reduced pressure. The residue is partitioned between 50 mL of ethyl acetate and 50 mL of water. The aqueous layer is extracted with 50 mL of ethyl acetate and the organic extracts are dried (sodium sulfate) and the solvent removed in vacuo. The residue is chromatographed (silica gel, 2% methanol/98% dichloromethane) to give 2.15 g of the title compound; mp 92.8°-93.9° C.
In a process analogous to Example 13 using appropriate starting materials the corresponding compounds of Formula I (Examples 14 to 19) are prepared as follows:
EXAMPLE 14
3-[5-3,6-Dihydro 4-(2-thienyl-1(2H)-pyridinyl]-butyl quinoline; mp 73.8°-74.8° C.
EXAMPLE 15
3-4-[3,6-Dihydro-4 (2-pyridinyl)-1(2H)-pyridinyl -butyl]quinoline; mp 81.2°-81.6° C.
EXAMPLE 16
3-[3-[3,6-Dihydro-4-(2-thienyl)-1(2H)-pyridinyll-propyl]quinoline.
EXAMPLE 17
3-[3-(3,6-Dihydro 4 phenyl-1(2H]-pyridinyl)propyl]-quinoline dihydrochloride salt; mp 166°-67° C.
EXAMPLE 18
3-5-3,6-Dihydro-4-(2-thienyl)-1(2H)-pyridinyl -pentyl]quinoline.
EXAMPLE 19
3-[5-(3,6-Dihydro4-phenyl-1(2H)-pyridinyl)pentyl]-quinoline dihydrochloride salt; mp 162°-163° C.
PREPARATION OF STARTING MATERIALS
Example 4
4-(4-Pyridinyl)-1-butylchloride
A solution of 4-(4-pyridinyl)-1-butanol (Mayer J. M. and Testa, B., -Helv. Chim. Acta 65, pages 1868-1884 (1982) (4.20 g, 27.7 mmol) in 30 mL of chloroform is cooled to 0° C. and treated with thionyl chloride (6.60 g, 55.54 mmol) in 30 mL of chloroform. The reaction is allowed to warm to room temperature over 15 hours. The volatiles are removed in vacuo. The residue is cooled to 0° C. and treated with 50 mL of cold 10% sodium hydroxide solution and the mixture is extracted with three 100-mL portions of chloroform. The combined organic extracts are dried over sodium sulfate and the solvents are removed under reduced pressure to give 4.25 g of 4-(4-pyridinyl)-1-butylchloride as a brown oil.
In a process analogous to Example A using appropriate starting materials the corresponding compound was prepared as follows:
Example B
3-(4-Pyridinyl)-propylchloride (Mayer, J. M. and Testa, B., Helv. Chim. Acta, pages 1868-1884 (1982)).
Example C
5-(4-Pyridinyl)-pentylchloride
Step
A: Preparation of 4-(Chlorobutoxy)-3,4,5,6-2H-tetrahydropyran
A solution of 4-chlorobutanol (23.2 g, 0.2140 mol) and 2 drops of concentrated hydrochloric acid at 0° C. is treated with 3,4-dihydro-2H-pyran (15 g, 0.1 783 mol). The reaction is allowed to warm to room temperature over 3 hours. The reaction mixture is purified by distillation (130° C., 20 mm) to give 18.07 g of 2-(4-chlorobutoxy)-3,4,5,6-2H-tetrahydropyran as a colorless oil.
Step B
Preparation of 5-(4-Pyridinyl)-1-pentanol
Phenyl lithium (1.8 M cyclohexane diethyl ether, 27.6 mL, 0.0497 mol) is slowly added to a stirring solution of 4-picoline (4.6 g, 0.0497 mol) in 50 mL of tetrahydrofuran under nitrogen. The solution is stirred for 20 minutes at room temperature and then cooled to 0° C. 2-(4 Chlorobutoxy)-3,4,5,6-2H-tetrahydropyran (6.4 g, 0.0332 mol) is slowly adde to the reaction mixture and the mixture is stirred for 30 minutes at 0° C. The reaction mixture is refluxed for 12 hours, cooled, and 100 mL of 10% hydrochloric acid solution is added. The reaction mixture is stirred for another 12 hours and then made basic with a saturated solution of sodium bicarbonate and extracted with chloroform. The organic phase is dried (sodium sulfate) and evaporated in vacuo. The resulting residue is chromatographed on silica gel (ethyl acetate) to give 1.25 g of 5-(4-pyridinyl)-1 pentanol as a brown oil.
Step C
Preparation of 5-(4-Pyridinyl)-1-pentyl-chloride
A solution of 5-(4-pyridinyl)-l-pentanol (3.71 g, 0.0225 mol) in 50 mL of chloroform is treated with thionyl chloride (5.4 g, 0.0449 mol) in 25 mL of chloroform. The resulting solution is neutralized with a saturated solution of sodium bicarbonate and extracted with chloroform. The organic phase is dried (sodium sulfate) and evaporated in vacuo to give 3.86 g of 5-(4-pyridinyl)-1-pentylchloride as a brown oil.
Example D
4-Chloro-1-(3-pyridinyl)-1-butanone (Sato, M., et al, Chem. Pharm. Bull., 26, 3296 (1978))..
A solution of methyl nicotinate (59 g, 0.43 mol), 4 hydroxybutyric acid lactone (51.8 g, 0.602 mol), and sodium methoxide (70 g, 1.29 mol) in dioxane (500 mL) is refluxed for 1 hour and then cooled. Concentrated hydrochloric acid (650 mL) is added, and the reaction mixture is refluxed for 12 hours. The resulting solution is neutralized with solid sodium bicarbonate and extracted with chloroform. The organic phase is dried (sodium sulfate), and the solvent evaporated in vacuo. The residue is taken up in 2-propanol (50 mL) and treated with a saturated solution of hydrogen chloride in 2-propanol. The hydrochloride salt of 4 chloro-1-(3-pyridinyl)-1-butanone is obtained as a white solid (30 g); mp 73°-76° C.
Example E
4-(3 Quinolinyl)butan-1-ol
Step A
Preparation of 4-(3-Quinolinyl) 3-butyn-1-ol
A solution of 3-bromoquinoline (13.57 mL, 0.10 mol) and 3-butyn-1 ol (9.0 mL, 0.12 mol) in 40 mL of triethylamine and 75 mL of dichloromethane is degassed by bubbling dry nitrogen through it for 15 minutes, and 0.7 g (0.00I mol) of bis(triphenyl-phosphine)palladium dichloride and 0.013 g of cuprous iodide are added. The flask is flushed with nitrogen and the mixture heated to reflux for 5 hours. The cooled mixture is diluted with dichloromethane and washed with water, dried (sodium sulfate), and concentrated to give 27 g of a gold oil. The oil was triturated with diethyl ether to give 18.2 g of the title compound as a tan solid; mp 95.7°-96.7° C.
Step B
Preparation of 4-(3-Quinolinyl)butan-1-ol
A solution of 4-(3-quinolinyl)-3-butyn-l-ol (17.0 g, 0.086 mol) is hydrogenated over palladium on carbon (1.0 g) in ethanol (400 mL) at room temperature. After the catalyst is filtered, the solvent is removed under reduced pressure to give 17.3 g of a brown oil. The oil is chromatographed (silica gel, 2% methanol/98% dichloromethane) to give 13.5 g of the title compound as a yellow oil. | Substituted tetrahydropyridines and derivatives thereof are described, as well as methods for the preparation and pharmaceutical composition of same, which are useful as central nervous system agents and are particularly useful as dopaminergic, antipsychotic, and antihypertensive agents as well as for treating hyperprolactinaemia-related conditions and central nervous system disorders. | 2 |
BACKGROUND
The present invention relates generally to entertainment and training systems, and more particularly, to a video display system that may be employed in a moving vehicle entertainment or training system.
There are several examples of group interactive video entertainment systems that are in various stages of research, development, and test marketing. Hughes Training Inc. has a system known as "Mirage" that is a typical embodiment of a group interactive video entertainment system. The Mirage system utilizes batch processing of small groups of game players, and requires that a queue of players advance in relatively widely-spaced discrete steps. The waiting time between advances in the queue is perceived as a prime irritation factor by the public, in that there is no progress for long periods of time.
Accordingly, it would be an improvement in the art to have a video display system that may be employed in a moving vehicle entertainment system that increases the processing speed of participants through the system, thus eliminating the waiting time problem present in existing systems.
SUMMARY OF THE INVENTION
In order to achieve the above improvement, the present invention provides for a video display system that enables the operation of a group interactive entertainment system known as "Tunnel Vision Adventure", that is generally described in copending U.S. patent application Ser. No. 07/765,847 filed Sep. 23, 1991, and assigned to the assignee of the present invention. The video display system of the present invention provides a low cost means by which a high volume of participants may be processed through an interactive video entertainment system in an rapid manner. The display medium is comprised of walls of a serpentine darkened tunnel constructed of flat faceted rear projection screens, upon which video imagery is projected from video projectors disposed outside the tunnel behind the rear projection screens. Participants traverse through the darkened display tunnel riding in-vehicles that are guided and driven in a manner analogous to automobiles processed through a car wash or factory assembly line.
The video display system of the present invention provides the means by which an operator of an amusement park ride or training system may quickly and efficiently process a large number of participants. The video display system enables the use of efficient video rear projection technology in a demanding consumer environment that exhibits aspects of both a production line and an auditorium.
The video display system of the present invention allows an entertainment or training system designer to break up the participant batch size into much smaller groups, thus minimizing intergroup waiting time, and removing some of the frustration due to waiting for those participants in the queue. The system throughput is sufficiently high as to be perceived as continuous by participants. The video display system of the present invention permits the highest participant throughput of any known interactive and/or reconfigurable video presentation system.
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 shows a perspective view of a tunnel vision video display system in accordance with the principles of the present invention; and
FIG. 2 shows a diagram illustrating the details of the video display system of FIG. 1.
DETAILED DESCRIPTION
Referring to the drawing figures, FIG. 1 shows a perspective view of a video display system 10 in accordance with the principles of the present invention. The video display system 10 is shown in the context of a moving vehicle entertainment system 11 that comprises a plurality of moving vehicles 12 that are propelled along a track, for example, inside a darkened tunnel 13. The vehicles 12 in FIG. 1 are shown as automobiles for the purposes of illustration, and it is to be understood that other vehicle shapes, including spaceships, boats, airplanes or moving platforms are also appropriate for use in the present system 10. Each of the vehicles 12 has audio reproduction system therein along with appropriate instruments that enable the participants to interact with a video image and respond to audio cues provided thereto. Such instruments are specifically designed for a system 11, for example, and may comprise steering yokes or joysticks, and surrogate weapons, such as cannons, ray guns and pistols, for example. The details of these instruments may be better understood from a reading of the above-cited Tunnel Vision Adventure patent application. It is also to be understood that the present system 10 may also be employed in training systems, for example, that require the processing of relatively large numbers of participants.
The darkened tunnel 13 is formed from a plurality of faceted sections 14 that each comprise a plurality of trapezoidal and rectangular flat rear projection screens 15 and that are formed in the shape of the tunnel 13. Three sections 14 of the tunnel 13 are shown in FIG. 1, wherein each section 14 is fabricated from five individual flat rear projection screens 15. The five-screen sections 14 are then replicated along the length of the tunnel 13 to form the complete tunnel 13. The tunnel 13 may be configured as a serpentine tunnel 13 as will be described in detail below. A plurality of video projectors 17 and mirrors 18 are provided that cooperate to focus video images 19 provided by the projectors 17 onto the rear of each of the projection screens 15. The video images 19 projected by the video projectors 17 are controlled by a computer processor 20 having a visual database 21 that includes computer graphics, and the like. The computer processor 20 is coupled to each of the projectors 17 and is adapted to control the audio and video images 19 viewed by participants moving in the vehicles 12 that are propelled through the tunnel 13. It is to be understood that interconnection paths shown between the central processor 20 and the projectors 21 and vehicles 12 are shown for illustration only, and are not to be considered as limiting.
More specifically, the video display system 10 comprises a flat faceted tunnel 15 incorporated five rear projection screens 15 or panels 15 per section 14. The basic rear projection facet (screen 15) and video projector arrangement are disclosed in a patent application entitled "Rear Projection Faceted Dome", U.S. patent application Ser. No. 07/704,571, filed May 13, 1991, that is assigned of the present invention. The facets or screens 15 of the present system 10 are arranged in the shape of a serpentine tunnel 16. The vehicles 12 that seat participants are propelled down the center of the tunnel 16, and a design eyepoint (in lateral cross section), that corresponds to the position at which a participant's eye level is located, is designed to be at an eye level for seated occupants in the vehicles 12. The moving design eyepoint is designed to be approximately at a longitudinal center of the vehicle 12 at eye level.
Moving imagery without moving parts is provided by the system 10 of the present invention. One unique aspect of video display system 10 is that it contains no moving parts, in that the projectors 17, mirrors 18, and projection screens 14 are stationary. Notwithstanding the absence of moving parts, however, the occupants of each vehicle 12 are presented with video images 19 unique to that vehicle 12. Moreover, the imagery "moves" in synchronization with the vehicle 12 as it traverses the tunnel 15, allowing the designer of the entertainment system 11 to take advantage of the entire length of the tunnel 15. The image content, however, is dynamic, and is synchronized by means of the computer processor 20 to correspond with the movement of the vehicles 12. The motion effects and image content are controlled by the computer processor 20. The present system 10 has the ability to provide the illusion that a vehicle 12 is standing still, when the image content is synchronized with the forward motion of the vehicle 12. Similarly, any visual aspect of motion may also be presented to the occupants of the vehicle 12 by utilizing a mathematical manipulation of image perspective. In essence, a vector representing actual vehicle motion is uniformly applied to the overall image, but in projection screen space. Simulated motion is applied to the image content, but in database space, where changes in perspective and occlusion may be processed correctly. Such mathematical manipulation is achieved in the computer processor 20 in a straightforward manner known to those skilled in the art of real-time computer graphics processing.
Synchronization to special effects is also achieved by the video display system 10, including motion cuing. While a vehicle 12 progresses along the tunnel 13 in real world terms, it experiences simulated motion effects that cover six degrees of motion. Hydraulic actuators are employed in the vehicles 12 that provide actual motion cues in synchronization with visual motion cues provided by the images 19. The hydraulic actuators are controlled in a conventional manner by the computer processor 20. By applying means and methods developed for flight simulation motion base simulators and pneumatic technologies employed in "low rider" automobiles that are quite prevalent in Southern California, the sensation of nearly unlimited translational and rotational movement may be effected in a straightforward manner in the system 10. Sound cuing is also provided in the video display system 10. Cues may be provided by headphones worn by the participants, or by the speakers provided in the vehicles 12. A sound or audio reproduction system is located in each of the vehicles 12, or may be located adjacent the central processor 20. It is used to direct attention and augment visual cues appearing in images 19 appearing on the walls (screens 15) of the tunnel 13. Directionality is achieved through the utilization of multichannel sound rendition that correlates to events appearing in the imagery. This is also controlled in a conventional manner by the computer processor 20.
Separation of imagery between vehicles is also provided by the video display system 10. The video display system 10 takes advantage of the inherent limitations of the rear projection screen 15 for off-axis viewing. The gain characteristics of each rear projection screen 15 is selected to cause the image to dim to less than 50 percent of its center brightness when viewed from more than 60° off axis. Each facet or screen 15 is approximately eight feet tall and twenty feet long, yielding a field of view of approximately 37°×80° for a vehicle 12 positioned directly opposite it. As the vehicle 12 progresses down the tunnel 13, the five facets 15 comprising the section 14 immediately surrounding the vehicle 12 are illuminated, together with the preceding and succeeding facet sections 14. As the vehicle 12 transitions from the center to the forward section 14, the rearward section 14 is extinguished and the forward section 14 in line is illuminated. The forward section 14 intensity is gradually increased as the vehicle 12 approaches, making the transition nearly undetectable. Since the attention of the participants in the vehicle 12 is focussed in a forward direction, the extinguishing of the rear section 14 is more abrupt. The convincing illusion presented to the occupants of the vehicle 12 is that of horizon-to-horizon imagery surrounding the vehicle 12, with a dark hole ahead of and behind the vehicle 12. The intervehicular spacing is such that the imagery presented to one vehicle 12 is not viewable from another vehicle 12, theoretically enabling vehicle spacing as close as twenty-five feet.
FIG. 2 shows a diagram illustrating the details of the video display system 10 of FIG. 1. Equipment configuration considerations for the video display system 10 are as follows. For each section 14, comprising five facets or screens 15 each, five rear projection screens 15 and five projectors 17 are required. This is shown in detail in FIG. 2. It is to be understood that a wide variety of projector and mirror positioning geometries are possible with the present system 10, and the specific locations and orientations shown in FIG. 2 are for the purposes of illustration only, and are not to be considered as limiting. The resolution achieved by a system 10 with 512 lines×1024 pixel rasters on the rear projection screens 15 is between twelve and fifteen arc minutes per line pair, which is comparable to conventional training and entertainment systems. Standard 1024×1024 image generation channels are split between two rear projection screens 15, yielding a utilization of 2.5 image generation channels per rear projection screen 15.
The layout of the tunnel 15 is achieved as as follows. Turns of up to 30° may be made between sections 14 along any of the five section joints. At a turn, the sections 14 become trapezoidal, and shorter than their standard length. This allows for a serpentine tunnel layout to be implemented in a structure similar to a multi-story parking garage. Since real world vehicle velocity and position are subtracted from the eyepoint motion vector, great flexibility is achieved, with intertwining ascending and descending vehicle ramps allowing for a significant length of tunnel 15 to be packed into a relatively small structure.
The video display system 10 of the present invention is applicable for use in the mass entertainment market, most notably in an amusement or theme park setting. There are other applications in training and personnel processing markets, most appropriate to situations wherein large numbers of people are involved, such as in encountered in a military setting.
Thus there has been described a new and improved video display system that may be employed in a moving vehicle entertainment or training system. It is to be understood that the above-described embodiment is merely illustrative of some of the many specific embodiments which represent applications of the principles of the present invention. Clearly, numerous and other arrangements can be readily devised by those skilled in the art without departing from the scope of the invention. | A video display system provides low cost, rapid processing for a high volume of participants through an interactive video system. The system includes a darkened serpentine tunnel constructed of flat faceted rear projection screens, formed as series of multi-screen sections. Video imagery is projected onto the screens from video projectors using reflecting mirrors on the back sides of the screens. The screens are mated together to form the complete tunnel. Participants travel through the darkened tunnel riding in guided vehicles. As each vehicle progresses through the tunnel, the projection screens currently surrounding the vehicle are illuminated, together with the preceding and succeeding screen sections. As the vehicle transitions from the current section to the forward section, the rearward section is extinguished and the next forward section illuminated. The image intensity of the forward section is gradually increased as the vehicle approaches, by virtue of the gain characteristics of the projection screen, thus making the transition nearly undetectable. | 7 |
CROSS REFERENCE TO RELATED APPLICATION
This application is related to U.S. patent application Ser. No. 267,088, filed Nov. 3, 1988 now abandoned and assigned to the same assignee as the present application.
BACKGROUND OF THE INVENTION
The invention relates to a method and apparatus for providing optimum radar elevation patterns at long and short ranges, and more specifically, to a method and apparatus for transmitting high energy pulses, also referred to as long pulses, in a first optimum beam pattern for detection of targets at long ranges, and transmitting low energy pulses, also referred to as short pulses, in a second optimum beam pattern for detection of targets at short ranges, in surveillance radar using solid-state transmitters.
Solid state transmitters are gradually replacing magnetron and klystron transmitters. Although providing numerous advantages over magnetron and klystron transmitters, solid state transmitters have one drawback in that they generate low peak power. Consequently, sufficient energy for long range detection can be provided only by transmitting long pulses. However, the longer the pulse, the farther away the object must be to ensure that its echo is not distorted by a transmitted pulse unavoidably present in the receiver. For example, if a pulse of 100 μs is transmitted, the target must be at least 8 nautical miles (nmi) away from the transmitter before its entire echo can be received undistorted. Exceedingly strong short range clutter echoes complicate reception such that only echoes beginning several nautical miles beyond the end of the transmission can be received without distortion.
Long pulses for solid-state radars can be coded to provide the bandwidth necessary for the desired range accuracy and resolution. Echoes received are decoded or "compressed" into short pulses, but some undesired energy known as "range sidelobes" extend as much as the transmitter pulsewidth to either side of the desired short pulse, obscuring weaker echoes from neighboring targets. If the uncompressed echo is distorted by strong overlapping interference (transmitted pulse or short range clutter echoes) exceeding the linear dynamic range of the receiver, the range sidelobes grow larger, making it impossible to detect the presence of a small aircraft at the same azimuth as a large aircraft, unless their range separation exceeds the transmitter pulsewidth. This is unacceptable for airport surveillance radar (ASR), where collision avoidance between large commercial airliners and small general aviation aircraft is of prime concern.
Thus, since long pulses cannot be utilized to accurately detect targets at short ranges, it is necessary to transmit separate long and short pulses to provide long range and short range coverage, respectively. Examples of ASR systems utilizing this technique are the RAMP PSR manufactured by the Raytheon Corp. and the AN/TPS-73 manufactured by the Selenia/Unisys Corps.
FIG. 1 is a graph showing exemplary coverage patterns for the RAMP PSR. The coverage patterns show target locations where the circularly polarized radar provides 80% probability of detection of a two square meter target. Coverage patterns 10 and 14 result from transmission and reception on the same beam. Coverage pattern 12 results from reception on a higher elevation beam and cannot be employed past 20 nmi without losing coverage of low altitude aircraft.
The long range pulses, corresponding to beam patterns 10 and 12, are 100 μs in length, and the short range pulses, corresponding to coverage pattern 14 are 1 μs in length. The long range coverage pattern presumes no ground clutter interference. At short range, echoes from terrain or sea create clutter interference which must be suppressed by the use of filters which reject their low Doppler frequencies, sometimes called moving target indicators (MTI). As is well known in the radar art, Doppler filters introduce losses in sensitivity, even when they are able to attenuate clutter echoes well below receiver noise.
A first loss, estimated to be 4 dB in computing coverage pattern 14, is caused by the correlation of receiver noise by the Doppler filter, reducing the effectiveness of integrating the multiple samples received during the time that the antenna beam dwells on a target. The reduction of the effective number of pulses integrated causes an increase in the average echo power required to achieve a given detection probability. This sensitivity loss is exaggerated by signal processing to control the false alarm rate in rain or jamming environments.
A second loss is created when the target has an unfavorable Doppler frequency, even though outside the clutter rejection notch. The gain of the Doppler filter varies as a function of the target range rate. This is known as velocity response. "Blind speeds" are those speeds with response more than 20 dB below average, and "dim speeds" create more modest loss. Operational utility of a radar depends on detecting targets at a large fraction (90-99%) of possible range rates, therefore, velocity response loss shrinks coverage 14.
The peak power of the signal used for both the long and short pulses is the same. However, the short pulse contains approximately 20 dB less energy. The short pulse sensitivity, including 4 dB average Doppler filtering loss, is 24 dB less than the long pulse, shrinking the coverage of the short range beam pattern in both range and altitude by a factor of 4. As a result, as is apparent in FIG. 1, an area 16 exists in the coverage pattern above approximately 10,000 feet for distances within approximately 10 nmi of the radar transmitter where neither the long range nor short range beam patterns provide aircraft detection. This area 16 is referred to herein as a "hole" in the coverage pattern. Any "hole" in the coverage pattern of a radar system is, of course, a serious problem.
As described, the coverage pattern 14 in FIG. 1 and to a two square meter aircraft with a range rate resulting in 0 dB signal-to-noise gain from the Doppler filter. A smaller aircraft or a range rate corresponding to a "dim speed" would create a much larger "hole" in the critical coverage region of an ASR system.
The beam coverage pattern 10 shown in FIG. 1 also exaggerates clutter interference, providing about 22 dB higher gain to hills in the nose of the beam patterns than to aircraft at elevation angles between 15° and 35°. Receiving the long range pulse over a higher elevation pattern, such as beam pattern 12, is helpful in reducing this clutter exaggeration in the 10 to 30 nmi range, but it is substantially ineffective in the short range region. In particular, at approximately the 5 nmi range, a hill has to be only 1,500 feet above the airport (approximately 3° of elevation) to create stronger clutter echoes in the high beam 12 than in the low beam 10.
The only known prior solution to correct for inadequate range coverage is to increase the peak power of the transmitted pulses by about 40%. This permits the long pulse length to be shortened to approximately 70 μs which moves the long range beam coverage closer to the transmitter to about 7.5 nmi, and provides sufficient energy to the short pulse to cover out to about 7.5 nmi for a specified aircraft cross-section at average Doppler. However, increasing the peak power of the transmitted pulses significantly increases the cost of the transmitter. Also, provision of an adequate safety factor of power to cope with "dim speeds" or smaller aircraft cross-sections becomes very costly and causes even more saturation of clutter echoes.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide a method and apparatus for providing a less costly solid-state transmitter capable of providing complete long and short range beam pattern coverage for a radar system such as an ASR.
It is another object of the present invention to provide a method and apparatus for transmitting and receiving high energy pulses over a first beam pattern for accurately detecting targets at long ranges and for transmitting and receiving low energy pulses over a second beam pattern for accurately detecting targets at short ranges.
Additional objects and advantages of the invention will be set forth in the description which follows, and in part will be apparent from the description, or may be learned by practice of the invention. The objects and advantages of the invention may be realized and obtained by means of the methods, instrumentalities and combinations particularly pointed out in the appended claims.
To achieve the foregoing objects, and in accordance with the purposes of the invention as embodied and broadly described herein, a radar apparatus is provided for providing radar coverage, comprising: a waveform generator for generating high-energy pulses and low-energy pulses; a waveform splitter connected to the waveform generator for splitting each of the high-energy pulses and low-energy pulses into first and second signals; a differential phase shifter connected to the waveform splitter for receiving the first and second signals; a beam forming matrix connected to the differential phase shifter; an array antenna connected to the beam forming matrix; and a controller connected to the differential phase shifter and providing a first control signal to the differential phase shifter to shift one of the first and second signals input to the differential phase shifter relative to the other of the first and second signals input to the differential phase shifter when the waveform generator generates the low-energy pulses.
Also in accordance with the invention, a pair of amplifiers is provided between the differential phase shifter and the beam-forming matrix to increase the peak power and energy content of the radiated pulses.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate a presently preferred embodiment and method of the invention which, taken with the general description given above and the detailed description of the preferred embodiment and method given below, serve to explain the principles of the invention. Of the drawings:
FIG. 1 is a graph of long and short range coverage patterns of a known ASR system;
FIG. 2 is a block diagram of an ASR system in accordance with the present invention;
FIG. 3A is a timing diagram for generating long (high-energy) and short (low-energy) pulses in an ASR having a single receiver.
FIG. 3B is a timing diagram for generating long (high-energy) and short (low-energy) pulses in an ASR having a pair of receivers.
FIGS. 4A-4D illustrate the phase relationship between output signals of a differential phase shifter in response to first and second control signals.
FIG. 5 is a graph of long and short range elevation beam patterns in accordance with the present invention which eliminate the coverage "hole" of FIG. 1.; and
FIG. 6 is a graph illustrating long and short range coverage patterns of an ASR system in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 2 is a block diagram of a preferred embodiment of an ASR system for providing complete radar coverage and preventing the occurrence of "holes" in long and short range coverage patterns. The system includes waveform generator 20, waveform splitter 22, differential phase shifter 24, controller 26, amplifiers 32 and 34, transmit beam-forming matrix 36 and array antenna 38 which may radiate either directly to a target or indirectly via a reflector or lens (not shown). Dashed line 52 indicates the preferred location of a rotary joint (not shown).
Controller 26 is connected to waveform generator 20 via line 40 and differential phase shifter 24 via line 46. Waveform generator 20 is coupled via line 21 to waveform splitter 22, which provides two inputs 42 and 44 to differential phase shifter 24. Amplifiers 32 and 34 are connected to differential phase shifter 24 via lines 48 and 50, respectively, and to transmit beam-forming matrix 36 via lines 56 and 58, respectively. Transmit beam forming matrix 36 is connected to each horizontal row of array antenna 38 via a plurality of connection lines 37.
FIGS. 3A and 3B illustrate examples of long and short pulses used to provide the desired coverage patterns according to one embodiment of the present invention. FIG. 3A corresponds to an ASR having a single receiver for receiving both beams sequentially. The 1 μs pulse is emitted by array antenna 38. This is followed by a period of 125 μs in which to detect the echo of the 1 μs pulse from a target less than 10 nmi from the radar. After this 125 μs period, the 100 μs pulse is emitted by array antenna 38. More than 1,000 μs are then provided to allow for detection of the echo of the long pulse from a target between 10 nmi and a maximum instrumented range. Further, a delay of 24 μs is provided between the trailing edge of the transmitted pulse and the leading edge of an echo from the 10 nmi range because clutter echoes may saturate the receiver during that time period. Using sequential reception, the frequencies of the long and short pulses f 2 and f 1 , respectively, are preferably different. However, these frequencies could be the same if the extent of mutual interference is considered acceptable.
FIG. 3B illustrates examples of long and short pulses used to provide the desired coverage patterns in an ASR having a pair of receivers for simultaneous beam reception. A 100 μs pulse is transmitted by array antenna 38 followed closely by the short pulse of 1 μs. For simultaneous reception, long and short pulses have different frequencies f 2 and f 1 . From 0 to 125 μs after transmission of the short pulse, detection of the echoes from this pulse are provided by a first receiver. From 24 μs to more than 1,000 μs after transmission of the long pulse reception of an echo from the long pulse is provided by a second receiver.
Operation of the ASR system shown in FIG. 2 is as follows. In response to signals on line 40 from controller 26, waveform generator 20 generates short and long transmission pulses at appropriate intervals. These pulses are output to waveform splitter 22, where they are split into equal or unequal signals and output on lines 42 and 44 to differential phase shifter 24. During an interval in which waveform generator 20 generates a short pulse, controller 26 also outputs a first control signal on line 46 to differential phase shifter 24 to create a first phase relationship between signals output by differential phase shifter 24 on lines 48 and 50.
Because the gains of amplifiers 32 and 34 may not be equal and their phase transfer functions may not match over wide bandwidths, the relative amplitude and phase conditions on lines 48 and 50 may differ from the conditions desired on lines 56 and 58. Thus, the first phase relationship between the signals on lines 48 and 50 may be frequency dependent to overcome any unbalance in phase characteristics of amplifiers 32 and 34.
The signals output by amplifiers 32 and 34 on lines 56 and 58, respectively have a fixed phase relationship. For example, the signal on line 58 may be shifted 180° from the signal on line 56. During an interval in which waveform generator 20 generates a long pulse, controller 26 outputs a second control signal on line 46 to create a second phase relationship between the signals output by differential phase shifter 24 on lines 48 and 50. Again, amplifiers 32 and 34 provide a fixed phase relationship between these signals output on lines 56 and 58. For example, the signals on lines 56 and 58 may have 0° phase shift.
FIGS. 4A and 4D illustrate these first and second phase relationships. FIGS. 4A and 4B illustrate the carrier waveform on lines 56 and 58, having frequency f 1 . As shown, the amplitude of the signal on line 56 (FIG. 4A) is greater than that on line 58 (FIG. 4B), however, the amplitudes may be the same. Moreover, the signal on line 58 (FIG. 4B) is shifted in phase 180° from the signal on line 56 (FIG. 4A).
FIGS. 4C and 4D illustrate the carrier waveform of the long pulse on lines 56 and 58, having frequency f 2 . The amplitude of the signal on line 56 (FIG. 4C) is shown greater than the amplitude of the signal on line 58 (FIG. 4D), however, these amplitudes may be the same. Moreover, these signals are in phase, i.e. shifted in phase by 0°. Thus, the first and second control signals output on line 46 by controller 26 to differential phase shifter 24 provide frequency dependent first and second phase relationships between the output signals on lines 48 and 50, respectively, and amplifiers 32 and 34 provide fixed first and second phase relationships between the signals output on lines 56 and 58, respectively.
The signals output by amplifiers 32 and 34, respectively, are input to inputs 60 and 62, respectively, of transmit beam forming matrix 36.
Although splitting the power equally is preferred, the power of the signal to be transmitted by antenna 38 may be split unequally between the signal at input 60 and signal at input 62 in the transmit beam forming matrix. For example, two thirds of the power may be in the signal at input 60 and one third in the signal at input 62 or vice versa. The desired coverage patterns are the vector sums of the patterns generated by inputs 60 and 62 individually, with two different differential phase conditions, for example, 0° and 180° phase shift.
Transmit beam forming matrix 36 may comprise the "Transmit Sum And Diff Beamswitch Network 58," "Low TX Beamformer 62" and "High TX Beamformer 68" described in co-pending U.S. patent application Ser. No. 267,088, filed Nov. 3, 1988. However, unlike in copending U.S. patent application No. 267,088 where separate rows of the array feed are used to generate a low beam and only a few of the rows are employed in both transmissions, in a preferred embodiment of the present invention, substantially all of the rows of antenna 38 are shared in generating the transmitted beams at low and medium elevation angles.
The resulting short range beam pattern formed by the transmit beam forming matrix 36 and output by antenna 38 is shown as reference numeral 66 in FIG. 5. The resultant long range beam pattern formed by the transmit beam forming matrix 36 and output by antenna 38 is shown as reference numeral 68 in FIG. 5.
The "optimum" beam pattern elevation for short range coverage is one having essentially constant two way gain (the product of the gain on transmission and reception) at all elevation angles of interest (1°-30° for ASRs). This provides equal gain to a target at all altitudes and avoids exaggerating clutter interference. If the same beam pattern is used for transmission and reception, the short range beam pattern 66 shown in FIG. 5 corresponds to this optimum beam pattern. Because the area under beam pattern 66 must equal that under beam pattern 68 in FIG. 5, when both are plotted in power units rather than dB, peak gain of pattern 66 is about 7 dB less than pattern 68. If the same pattern is used for reception, the echo is 14 dB below that of pattern 68 at optimum elevation.
Thus, by varying the phase of the two output signals from differential phase shifter 24, which are amplified and input to transmit beam forming matrix 36, the transmitted beam patterns generated thereby provide the appropriate power distribution to yield complete coverage in the short and long range beam patterns. This is illustrated in FIG. 6 where the short range coverage pattern 70 and the long range coverage pattern 72 provide no "holes" in the coverage.
In accordance with this embodiment, the long range coverage pattern 72 provides similar coverage as the coverage pattern 10 shown in FIG. 1 except that no coverage is required above an elevation angle corresponding to an aircraft at the maximum altitude of interest at the minimum range where echoes from this transmission are received. For example, coverage to 25,000 ft. beyond 10 nmi requires no transmission of energy above 24°.
Also in accordance with this embodiment, transmission of long range pulses occurs only on the low beam. Reception could occur on a high beam, not shown in FIG. 6, between 10 and 20 to 25 nmi, and on the low beam at longer ranges if two receivers are provided.
If the long range beam pattern 68 provides detection of the target to a range of 100 nmi at optimum elevation angle, the short range pattern 66 gain must not be more than 8 dB less at all elevation angles of interest to provide coverage at 10 nmi. A factor of 10 reduction in range corresponds to 40 dB reduction in sensitivity. Short range losses could consist of:
______________________________________Energy in short pulse = 20 dB less than long pulseAverage Doppler = 4 dBfiltering lossShort range TX gain = 8 dB less than long pulseShort range RX gain = 8 dB less than long rangeTotal short range = 40 dB less than longsensitivity in range sensitivityclutter area in clutter-free area______________________________________
Because the gain of the short range beam is estimated to be only 7 dB below that of the long range beam, and the atmospheric attenuation effect is much smaller at 10 nmi than at 100 nmi, several dB of excess average sensitivity is available at 10 nmi to offset some "dim speed" losses introduced by Doppler filtering.
Although identical beam patterns may be used for transmission and reception, multiple beam patterns may be desirable to provide height data, to lower transmitter power requirements, or to reduce clutter interference with targets at high elevation angles. In such cases, the transmitted beam pattern is altered to maintain the optimum two-way (transmit/receive) coverage patterns.
If multiple simultaneous receiver beams are employed, the switchable transmit pattern provides even greater benefits in reducing power requirements and in increasing signal to noise ratio at high angle targets. High gain on receive at low elevation reduces the energy required at these angles, where clutter is concentrated. The short range transmit beam provides higher gain to aircraft at higher elevation angles than to clutter to compensate differences in gain of the receive beams.
While there has been illustrated and described what are at present considered to be preferred embodiments and methods of the present invention, it will be understood by those skilled in the art that various changes and modifications may be made, and equivalents may be substituted for elements thereof without departing from the true scope of the invention.
In addition, many modifications may be made to adapt a particular element, technique or implementation to the teachings of the present invention without departing from the central scope of the invention. Therefore, it is intended that this invention not be limited to the particular embodiments and methods disclosed herein, but that the invention include all embodiments falling within the scope of the appended claims. | A method and apparatus are disclosed for providing optimum radar beam patterns to provide complete radar coverage at both short ranges and long ranges in a radar system using solid state transmitters. Long pulses for covering long ranges are generated and split into a pair of signals with a specific amplitude and phase relationship. These signals are provided to a transmit beam forming matrix of an array antenna to generate an optimum pattern for long range coverage. Short pulses are generated for providing short range coverage and are split into a pair of signals which are phase shifted differently from the long pulses. These signals are then provided to the transmit beam forming matrix to generate a different beam pattern for providing short range detection. The short range beam pattern has a sufficient amount of energy to provide coverage to maximum desired altitude over a range extending to where echoes from the long pulses may be received undistorted. | 6 |
TECHNICAL FIELD
[0001] This invention relates to a medical device and more particularly to a reinforcing ring used in stent graft device.
BACKGROUND ART
[0002] Stent grafts are used to bridge a defect in the vasculature of a patient and can be deployed into the vasculature endovascularly. This requires that the device can be constrained into a small delivery device and be able to expand or be expanded when release within the vasculature.
[0003] Where there are side branches to the vasculature it may be necessary to provide an aperture in the stent graft, known as a fenestration, to enable access from a deployed stent graft to that side branch. Such a fenestration may be reinforced with a peripheral circular ring stitched to the graft material around the fenestration. It is also desirable in some situations to provide a side branch stent graft extending through the fenestration and into the side branch.
[0004] PCT Publication WO 2005/034808 entitled “Fenestrated Stent Graft” describes the use of resilient reinforcing rings in stent grafts and the teachings therein are incorporated herein in their entirety.
[0005] To obtain a good seal of the branch stent graft within the fenestration an inflatable balloon can be used to expand the branch stent graft into the fenestration and for this purpose the reinforcing ring must be able to resist expansion of its diameter. At the same time the ring must be resilient so that it can be distorted into its deployment configuration but when released expand back to its circular configuration.
[0006] In this specification the term resilient when used in relation to a wire used to manufacture a reinforcing ring refers to a wire which is substantially inextensible but which has a spring function so that when distorted and released returns to its original configuration.
[0007] This invention will be discussed in relation to the application of a reinforcing ring to a fenestration but such a ring may have greater applicability.
[0008] Generally such a reinforcing rings is manufactured from a metal known as a superelastic metal such as, but not restricted, to a nickel titanium alloy known as Nitinol. To form a ring of a superelastic metal the desired final shape is formed from a wire on a former and then the wire on the former is heated above a temperature which sets the wire in the new shape. Upon cooling the ring holds it formed shape and can be distorted and resiliently returns to the formed shape.
[0009] The reinforcing rings discussed in PCT Publication WO 2005/034808 mentioned above when formed from a resilient wire each have substantially circular loops at the terminal ends of the wire. These loops prevent the sharp end of the wire puncturing the vasculature into which the stent graft is deployed. When it is desired to electropolish rings incorporating these prior art loops it is necessary to straighten out the ring but the prior art loops do not permit efficient electropolishing because parts of the loops touch the wire of the ring.
DISCLOSURE OF THE INVENTION
[0010] In one form therefore the invention is said to reside in a reinforcing ring for a fenestration of a stent graft, the reinforcing ring comprising a plurality of turns of a substantially inextensible resilient wire in a circular two dimensional shape and terminal ends at each end of the wire, the terminal ends each comprising a loop and a tail folded back and extending around the circular shape whereby the reinforcing ring can be straightened out for subsequent surface treatment with substantially no part of the circular shape, the loops or tails touching each other.
[0011] The substantially inextensible resilient wire can be a superelastic wire such as a wire formed from a nickel titanium alloy such as Nitinol.
[0012] The forming of the loop provides an end which is less likely to potentially damage the vasculature or a graft material. The provision of the tail which is folded back and extending around the circular shape enables the subsequent surface treatment to be carried out on all of the surfaces of the wire after it has been straightened out in a substantially linear manner.
[0013] Preferably there are substantially two circular turns of the wire.
[0014] In preferred embodiments the terminal loops at each end of the wire can overlap or be spaced apart either past each other or nearly reaching each other.
[0015] In one embodiment there are two complete circular turns of the wire and the loops extend further around the circular shape.
[0016] In one embodiment the terminal loops at each end of the wire can extend out of the plane of the circular shape at approximately right angles thereto.
[0017] In one embodiment each of the tails of the terminal loops comprises an enlarged end. The enlarged end can be in the form of a ball of solder or the like.
[0018] The subsequent surface treatment such may be polishing, passivation or coating. The polishing may be electropolishing, mechanical polishing or chemical polishing. According to the present invention these processes can be carried out on the entire surface of the reinforcing ring of the present invention because when it is straightened out no part of the loops or tails touch each other.
[0019] The process of passivation in relation to a nickel titanium alloy is intended to provide a protective nickel-depleted titanium rich oxide layer for good biocompatibility. Passivation also improves the corrosion resistance of the surface.
[0020] Electropolishing, also referred to as electrochemical polishing, is an electrochemical process that removes material from a metallic workpiece. It is used to polish, passivate and deburr metal parts. It is often described as the reverse of electroplating. It differs from anodizing in that the purpose of anodizing is to grow a thick, protective oxide layer on the surface of a material (usually aluminum) rather than polish.
[0021] For electropolishing typically, a metal work piece is immersed in a temperature controlled bath of electrolyte and connected to the positive terminal of a DC power supply, the negative terminal being attached to an auxiliary electrode. A current passes from the anode where metal on the surface is oxidized and dissolved in the electrolyte. At the cathode, a reduction reaction, normally hydrogen evolution, takes place. Electrolytes used for electropolishing are most often concentrated acid solutions having a high viscosity such as mixtures of sulfuric acid and phosphoric acid. Other electropolishing electrolytes reported in the literature include mixtures of perchlorates with acetic anhydride and methanolic solutions of sulfuric acid. To achieve electropolishing of a rough metal surface, the protruding parts of a surface profile must dissolve faster than the recesses. This behavior (referred to as anodic leveling) is achieved by applying a specific electrochemical condition, most often involving a mass transport limited dissolution reaction. A second condition for achieving polishing is that surface heterogeneities due to crystal orientation in a polycrystalline material are suppressed and that no pitting occurs. These conditions, often associated with surface brightening, are usually fulfilled with the above mentioned polishing electrolytes and with proper process control. Anodic dissolution under electropolishing conditions deburrs metal objects due to increased current density on corners and burrs.
[0022] Hence in the present invention, the reinforcing ring after it has been formed and suitably heat treated, as discussed above, so that it will return to its circular ring shape can be stretched out into a linear form so that no part of the ring touches another and then can be electrochemically polished or have some other surface treatment applied. Upon being released from its straightened out condition the ring will return to its circular ring shape.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] This then generally describes the invention but to assist with understanding reference will now be made to the accompanying drawings which show preferred embodiments of the invention.
[0024] In the drawings:
[0025] FIG. 1 shows a first embodiment of a reinforcing ring of the present invention;
[0026] FIG. 2 shows an alternative embodiment of a reinforcing ring of the present invention;
[0027] FIG. 3 shows an alternative embodiment of a reinforcing ring of the present invention;
[0028] FIG. 4 shows a reinforcing ring according to the embodiment shown in FIG. 2 stitched into a portion of graft material;
[0029] FIG. 5 shows a reinforcing ring according to the embodiments shown in FIGS. 1 to 3 stretched out for electropolishing;
[0030] FIG. 6 shows a stent graft incorporating fenestrations and a reinforcing ring according to the present invention;
[0031] FIG. 7 shows an alternative embodiment of the invention; and
[0032] FIG. 8 shows a leg extension stent graft incorporating a ring reinforcement of the embodiment of FIG. 7 .
DESCRIPTION OF PREFERRED EMBODIMENTS
[0033] Now looking more closely at the drawings and in particularly the embodiment shown in FIG. 1 it will be seen that the reinforcing ring 2 is formed into a two dimensional circular shape of a superelastic wire 4 . The ring has a diameter of from 5 to 15 mm when it is used as a reinforcing ring for a fenestration and from 10 to 40 mm when it is used as an end reinforcement for a tubular stent graft. The ring 2 is formed from a superelastic metal wire such as a nickel titanium alloy such as Nitinol. The wire can have a diameter of from 0.1 mm to 1 mm and preferably a diameter of from 0.15 mm to 0.3 mm.
[0034] The ring has nearly two turns of the wire 4 and each end of the wire terminates in a loop 6 and a tail 8 . The loop 6 is generally of a diameter through which can be passed a needle during stitching of the reinforcing ring into a graft material. Typically the loops may have a diameter of from 1 mm to 2 mm. The tail 8 extends back around the periphery of the reinforcing ring and when the wire is stretched out for passivation and/or electropolishing the tails are slightly spaced away from it (see FIG. 5 ). After electropolishing or other surface treatment and when the reinforcing ring is stitched into a stent graft there is no problem with the parts of the ring touching each other.
[0035] Each of the tails 8 ends in an enlarged end 9 . The enlarged end 9 can be for instance in the form of a ball formed from solder, fused material of the ring of the like. The enlarged end is provided to protect the fabric of a stent graft unto which the reinforcing ring is mounted from the sharp points at the ends of the wire and to assist the sewing of the end of the wire as a stitch can be added next to the ball which stitch can engage against the enlarged end or ball and prevents the wire from being pulled in one direction.
[0036] FIG. 2 shows an alternative embodiment of reinforcing ring according to the invention. The reinforcing ring 10 is formed into a two dimensional circular shape of a superelastic wire 12 . The ring 10 has two turns of the wire 12 and each end of the wire terminates in a loop 14 and a tail 16 . The loops 14 overlap each other. The tails 16 extend back around the periphery of the reinforcing ring and when the wire is stretched out for passivation and/or electropolishing the tails are slightly spaced away from it (see FIG. 5 ). Each of the tails 16 ends in an enlarged end 17 .
[0037] FIG. 3 shows an alternative embodiment of reinforcing ring according to the invention. The reinforcing ring 20 is formed into a two dimensional circular shape of a superelastic wire 22 . The ring 20 has two complete turns and a little more of the wire 22 and each end of the wire terminates in a loop 24 and a tail 26 . The tails 26 extend back towards each other. The tails 26 extend back around the periphery of the reinforcing ring and when the wire is stretched out for passivation and/or electropolishing the tails are slightly spaced away from it (see FIG. 5 ). Each of the tails 26 ends in an enlarged end 27 .
[0038] FIG. 4 shows a reinforcing ring according to the embodiment shown in FIG. 2 stitched into a portion of graft material. The graft material 30 has a fenestration 32 and around the fenestration is a reinforcing ring 10 retained in place by blanket type stitching 36 . In this embodiment the reinforcing ring 10 is of the type shown in FIG. 2 and the loops 14 overlap and two of the stitches of the stitching pass through the loops 14 . These extra stitches 37 are provided into the loops 14 and through the graft material. The tails 16 are also retained within the stitches 36 . It will be noted in particular that the stitch 36 a engages against the enlarged end or ball 17 .
[0039] FIG. 5 shows a reinforcing ring according to the embodiments shown in FIGS. 1 to 3 stretched out for passivation and/or electropolishing. The wire 40 is stretched essentially by pulling upon the tails 42 at each end out so that no portion of the rings, loops or tails touch another. It will be particularly noted that when stretched out the tail 42 does not touch the wire 40 thereby ensuring good electropolishing all over the wire.
[0040] FIG. 6 shows a stent graft incorporating fenestrations and a reinforcing ring according to the present invention. A stent graft 50 comprises a tubular wall body portion 53 . The tubular wall body portion is a biocompatible graft material such as Dacron, Thoralon, expanded PTFE material or a naturally occurring biomaterial, such as an extracellular matrix, such as small intestinal submucosa or other suitable material.
[0041] Gianturco style zig zag Z stents 55 are provided inside the graft material at each end and on the central tubular wall body portion Gianturco style zig zag Z stents 57 are provided on the outside of the graft material. There may be further Gianturco style zig zag Z stents than those illustrated depending upon the overall length of the stent graft 50 . Other forms of stent may also be used.
[0042] In the tubular wall body portion 53 there are two substantially circular fenestrations or apertures 59 on the tubular wall of the stent graft. In this embodiment there are two fenestrations being one for each of the two renal arteries when this embodiment is deployed into the aorta. Other numbers of fenestrations may also be used where the placement of the stent graft involves the possibility of occluding other branch vessels such as the superior mesenteric artery and the celiac artery. The fenestrations 59 are substantially circular. Radiopaque markers 61 are provided at each end of the fenestration 59 to assist a physician to locate the fenestration 59 in respect to a side vessel extending from a main vessel. The radiopaque markers 61 may be gold or other convenient material.
[0043] A reinforcement ring 62 of the present invention is provided around the periphery of the fenestration 59 to give good dimensional stability to the fenestration 59 . The reinforcing ring is manufactured from Nitinol wire. In an alternative arrangement the ring 62 may be formed from stainless steel or any other convenient material. Stitching 63 is provided to retain the ring 62 around the periphery of the fenestration 59 .
[0044] Also in FIG. 6 there is shown a scalloped fenestration 65 which opens to the end 67 of the stent graft.
[0045] FIG. 7 shows an alternative embodiment of the invention. In this embodiment the reinforcing ring 70 has nearly two full turns of Nitinol wire 72 and each end of the wire terminates in a loop 74 . Each of the loops extend out of the plane of the circular shape at approximately right angles thereto. The tails 76 of the loops extend around the periphery of the circular shape and each of the tails 76 ends in an enlarged end 78 .
[0046] The reinforcement ring of this embodiment is useful as a reinforcing ring at the end of a tubular body of graft material such as an arm or leg of a stent graft where the ring is stitched around the end of the tubular body and the loops at right angles to the plane of the ring extend along the tubular body and can be stitched thereto.
[0047] FIG. 8 shows a leg extension stent graft incorporating a ring reinforcement of the embodiment of FIG. 7 . In FIG. 8 the leg extension 80 has a tubular body 82 of a graft material and a reinforcement ring 70 at its proximal end 84 . The ring has loops 74 which extend out of the plane of the circular shape of the ring at approximately right angles and along the side of the tubular body. Stitching 86 fastens the ring to the tubular body and also some of the stitches pass through the loops 74 and over the tails 76 .
[0048] Throughout this specification various indication have been made as to the scope of the invention but the invention is not limited to any one of these but may reside in more than one combined together. The example and embodiments are given for illustration only and not for limitation. | A reinforcing ring ( 10 ) for a fenestration ( 32 ) of a stent graft which can be surface treated such as by passivation and/or electropolishing. The reinforcing ring has several turns of a substantially inextensible resilient wire ( 12 ) in a circular two dimensional planar shape and terminal ends ( 14 ) at each end of the wire. The terminal ends each comprising a loop ( 14 ) and a tail ( 16 ). The tail is folded back and extends around the circular shape. Each of the tails of the terminal loops can have an enlarged end. The reinforcing ring can be straightened out for surface treatment such as passivation and/or electropolishing with substantially no part of the circular shape, the loops or tails touching each other. | 0 |
BACKGROUND OF THE INVENTION
This invention is directed to a trajectory compensating device which includes a rifle scope having a reticle which has both a primary and secondary sighting plane and the elevational turret of the rifle scope having a turret cap which carries an indicia carrying member having a calibration mark and an indicator mark which allows for maintaining the trajectory of the bullet within a certain variable limit with regards to the line of sight to the rifle scope across both the primary and secondary sighting planes of the reticle.
One of the common problems associated with the use of rifle scopes is the inability of the shooter to correctly gauge the distance between his firearm and the target such that the elevational controls of the rifle scope can be correctly adjusted to reflect the distance. In order to compensate for this lack of distance judging ability separate range finders and/or rifle scopes with built-in range finders have been developed. The problem with these systems, however, is that they require extra time to use and if the shooter is attempting to hit a moving target such as a running deer most of the time the shooter simply does not even have time to adjust the elevational and windage turrets let alone use these devices prior to having to take a shot at the target before it disappears.
In U.S. Pat. No. 3,386,330 this problem with range finders is discussed. This patent attempts to overcome this problem by providing not a true range finder but an estimate or rapidly usable range finder. Further, this patent discusses how a bullet size and the load used in the cartridge holding that bullet will effect the trajectory of the bullet. That is, the trajectory of the bullet can result in a reasonable estimation of a point of impact error.
SUMMARY OF THE INVENTION
In view of the above it is an object of this invention to provide a trajectory compensating device which allows the shooter having once zeroed in his rifle scope to his firearm to set the elevational turret adjusting mechanism of the rifle scope on a predetermined mark and be assured that the trajectory of a bullet fired from the firearm will be within certain limits of error in striking a target. It is an additional object of this invention to provide a trajectory compensating device which because of its simplicity is readily adaptable to existing rifle scopes as well as being incorporated into custom designed rifle scopes.
These and other objects as will be evident from a remainder of the specification are achieved by providing a trajectory compensating device for use in combination with a rifle scope of the type having a reticle and a turret controlled elevational correction system including a turret which comprises: said reticle having a primary sighting plane and a secondary sighting plane; said turret including an indexing mark located on said turret; said turret including a turret cap operatively connected to said turret controlled elevational correction system so that said turret controlled elevational correction system is controlled by rotation of said turret cap about said turret; said turret cap including an indicia carrying means, said indicia carrying means including at least two individual indicia, said indicia carrying means located on said turret cap such that each of said individual indicia can be independently aligned with said indexing mark by rotating said turret cap; the first of said indicia on said indicia carrying means corresponding to a distance calibration mark wherein when said distance calibration mark is aligned with said indexing mark the line of sight through said rifle scope using said primary sighting plane of said reticle will be aligned with the center of impact on a target of a bullet of a fixed size expelled from a cartridge containing a fixed load down the muzzle of a firearm on which said rifle scope is mounted when said bullet is launched from said firearm concurrently with when said firearm is located at a distance from said target corresponding to the same distance being represented by said distance calibration mark; the second of said indicia corresponding to an indicator mark wherein when said indicator mark is aligned with said indexing mark and said bullet of said fixed side is expelled from said cartridge containing said fixed load down said muzzle of said firearm on which said rifle scope is mounted the trajectory of said bullet will first cross the line of sight through said rifle scope using said primary sighting plane of said reticle and next cross the line of sight through said rifle scope using the secondary sighting plane of said reticle and before said trajectory crosses said line of sight of said rifle scope using said primary sighting plane of said reticle the distance between said trajectory and said line of sight of said rifle scope using the primary sighting plane of said reticle as measured perpendicular from said line of sight of said rifle scope using said primary sighting plane of said reticle to said trajectory is not greater than a predetermined deviation distance and after said trajectory crosses said line of sight of said rifle scope using said primary sighting plane of said reticle but before said trajectory crosses said line of sight of said rifle scope using said secondary sighting plane of said reticle the distance between said trajectory and one of said lines of sight of said rifle scope using either said primary sighting plane of said reticle or said secondary sighting plane of said reticle as measured perpendicular from both said line of sight of said rifle scope using said primary sighting plane and said line of sight of said rifle scope using said secondary sighting plane of said reticle to said trajectory is not greater than said predetermined deviation distance.
The preferred turret cap of the invention will have at least a portion of its surface shaped as an upstanding cylinder which can readily receive the preferred form of the indicia carrying means which is an elongated strip having both the indicator mark thereon as well as at least one indicia corresponding to a distance mark. Additionally other distance marks can be included on the elongated strip to be used by the shooter when he is shooting at targets of known distances such as at a target range. Preferably the line of sight between the primary sighting plane of the reticle will be spaced from the line of sight of the secondary sighting plane of the reticle by three minutes of angle. This thus will result in the difference between the primary sighting plane and the secondary sighting plane giving lines of sight which are spaced apart from each other at 9 inches at 300 yards thus setting the deviation distance to be no greater than 41/2 inches.
BRIEF DESCRIPTION OF THE DRAWING
This invention will be better understood when taken in conjunction with the drawing wherein:
FIG. 1 is an isometric view of a turret of a rifle scope showing the preferred form of the turret cap of this invention and an example of the preferred form of an indicia carrying elongated strip attached thereto;
FIG. 2 is a plane view of a second example of the indicia carrying strip of FIG. 1 as it would appear if detached from the turret cap and located in a plane;
FIG. 3 is an end elevational view of the reticle of this invention is viewed through the eyepiece of a rifle scope incorporating the same;
FIG. 4 is a graph illustrating the use of the invention.
This invention utilizes certain principles and/or concepts as are set forth and defined in the claims appended to this specification. Those skilled in the art to which this invention pertains will realize that these principles and/or concepts could be utilized with a number of differently appearing embodiments differing from the embodiments described herein. For this reason this invention is to be construed in light of the claims and is not to be construed as being limited to the exact embodiment shown in the drawing and described in this specification.
DETAILED DESCRIPTION
Before describing how this invention operates or how the component parts of the invention interrelate to one another a simple listing of the few terms related to the invention is needed. The invention is adapted to fit onto a rifle scope which is mounted on a firearm. The firearm utilizes a cartridge which has a bullet located therein which is propelled by a load encased within the cartridge. No numbers are given for these components since they in fact do not form a part of this invention. However, in order to understand the invention it will be necessary to refer to these components.
In FIG. 1 a section of the barrel 10 of the rifle scope is shown. On this barrel 10 is a saddle 12 which carries for the purpose of describing this invention at least one turret 14. This turret 14 is the elevational turret. Normally the saddle 12 would also contain a second turret, a windage turret, which would be mounted on the other projection 16 located on the saddle 12. Since the windage turret forms no part of this invention it is not shown in FIG. 1. Located on turret 14 is a turret cap 18. This turret cap 18 contains knurled edges 20 around its upper perimeter which allow for ease of rotation of the cap 18. The cap 18 is connected to the internal mechanism of the turret 14 by a screw 22. This internal mechanism is one of any standard elevational correction mechanisms. The cap 18 has an upstanding cylindrical wall 24 around which is wrapped an elongated indicia carrying strip 26. At the base of the turret 14 is an indexing mark 27. This mark 27 is stationary with respect to rotation of the cap 18.
The indicia carrying strip 26 is better seen in FIG. 2 where it is stretched out in a flat plane. Located on the indicia carrying strip 26 are a plurality of distance markings collectively identified by the numeral 28 except for the 100 yard marking identified by the numeral 30. The 100 yard marking 30 for the purposes of this specification will be used as a calibration mark and will be referred to interchangeably either as the 100 yard mark or the calibration mark. It is to be understood that any of the distance marks 28 could also be used as a calibration mark but because of convention in calibrating a rifle scope and because of increased error as distance increases it is preferred to utilize the 100 yard mark as the calibration mark. In FIG. 2 located between the 200 and 300 yard distance marks 28 is an indicator mark 32.
Referring now to FIG. 3 one is viewing the reticle 34 as seen looking through the eyepiece of a rifle scope toward the objective end of a rifle scope. The reticle 34 has three supporting rods 36 and a bottom post 38. Connected to the supporting rods 36 and the bottom post 38 is a cross hair 40 which forms the primary sighting plane of the reticle 34. The top 42 of bottom post 38 forms a secondary sighting plane of the reticle 34.
FIG. 4 is a graph useful in understanding how the invention works. The horizontal axis lines refer to inches and are spaced apart from each other to represent 10 inches. Thus the graph vertically from top to bottom indicates from zero to 50 inches. The vertical axis lines of the graph represent yards and each vertical line is spaced apart from the other by a distance corresponding to 50 yards. The graph therefore covers from zero to 450 yards.
The capital M located at the zero inch and zero yard mark represents the exit end of the muzzle of a firearm. The capital S spaced above the capital M by a distance equal to approximately 11/2 graph inches represents the rifle scope.
Normally the rifle scope will be mounted above the muzzle of a firearm by a distance of approximately 11/2 inches and therefore this distance was chosen for the purpose of the graph of FIG. 4. The trajectory of a representative bullet exiting the muzzle M of a firearm is shown as line 44. Three other slope lines--zeroing slope line 46, primary sighting line 48 and secondary sighting line 50--are shown originating from the capital S. A vertical line 52 represents a line corresponding to the indicator mark 32. A dotted vertical line 54 is a cross-over line and an additional vertical line 56 indicates an approximate end of range line. A line labled 58 which is perpendicular to line 48 touches the trajectory line 44. This line will be identified as the deviation line 58. A line 60 crossing cross-over line 54 and trajectory line 44 is approximately perpendicular both to the primary line 48 and secondary line 50. This line 60 will be identified as the double deviation line. The line 60 is shown as approximately double in length as line 58; however, as hereinafter described can vary with respect to line 58.
For every given bullet size loaded in a cartridge having a particular sized load a trajectory is obtainable. Normally the manufacturer of the cartridges determine and provide the trajectory of the bullet of these cartridges. It is, however, possible for a marksman or hunter to calculate these trajectories by actually test firing the bullets using an appropriately fixedly held firearm and an accurately set up target range.
In using the trajectory compensating device of the invention an elongated strip 26 having a particular set of indicia located thereon as herein explained is mounted on the turret cap 18 as shown in FIG. 1. The firearm is then zeroed by sighting in the firearm to a center of impact of a group of bullets on a target at a known distance preferably 100 yards. For the remainder of this specification the 100 yard mark will be used as the distance in which the rifle is zeroed.
After zeroing, the screw 22 holding the cap 18 to the elevational correcting system of the rifle scope is loosened. The cap 18 is turned until the calibration mark 30 corresponding to the 100 yard mark is directly opposite the indexing mark 27 on the turret 14. Care is taken in doing this to ensure that the screw 22 is loose enough that when the cap 18 is turned the elevational correction system is not disturbed. When the calibration mark 30 is opposite the indexing mark 27 the screw 22 is tightened reconnecting control of the elevational correction system with the turret cap 18.
The trajectory 44 of the particular bullet and cartridge load can then be plotted as a line on a graph as shown in FIG. 4. From the trajectory as given by the manufacturer or as actually determined in test firing the known drop of the bullet at 100 yards is marked on the graph and the trajectory is connected through the muzzle point M to the 100 yard mark and beyond. The zeroing slope line 46 can be plotted if desired. An arbitrary deviation value is then chosen. This value is one which will equal an acceptable "hold-over or hold-under" value for the particular type of shooting which will be done. If big game is being hunted normally if the bullet strikes the target within 4 to 5 inches of its intended point of impact a kill will result. A hold-over or hold-under of 4 or 5 inches is therefore acceptable. Thus, for this type of shooting the deviation distance would be set at 4 to 5 inches. If target shooting is being done the shooter might require a closer deviation value and may set his limits even closer, i.e., 1 or 2 inches. In any event, a deviation value is chosen.
Using pre-existing tables such as those found in Ingalls' Ballistics Tables, computer calculations using known mathematical formulas or preparing graphs similar to the one shown in FIG. 4 it is possible to obtain a line 48 which will be no further from a trajectory line 44 than a predetermined deviation distance as represented by line 58. Given the trajectory of any bullet of a given weight or size loaded in any cartridge of a known load size a graph can be prepared which will yield a cross-over point between a primary sighting line 48 and the trajectory 44 of the individual bullet and load. Having obtained the cross-over point it is then possible to read off a graph a vertical line 52 and incorporate this vertical line 52 as an indicator mark 32 on an indicia carrying strip 26. Thus, a plurality of indicia carrying strips 26 can be prepared which correspond to a plurality of bullets and load sizes such as, for example, a 30-06 cartridge having a 110 grain load and a PSP bullet. Such a bullet when its trajectory is graphed would yield a vertical line 52 at 315 yards and thus on an elongated strip 26 the indicator mark 32 would be located close to the 300 yard mark between it and the 400 yard mark. A 30-06 cartridge using a 180 grain load and a PSPCL or ST bullet would yield an elongated strip 26 wherein the indicator mark 32 is at approximately the 280 yard mark as shown in FIG. 1. Likewise a 30-06 cartridge with a 220 grain load with a SPCL or PP(SP) bullet would yield an elongated strip 26 such as that shown in FIG. 2 wherein the indicator mark 32 is at approximately 255 yards.
Having determined an acceptable deviation difference the deviation difference can be plotted on the other side of the line 52 as one-half of line 60. This line is extended to its full length giving line 60 which is equal in value to double line 58. A secondary line 50 can then be drawn from point S to the bottom of line 60. On the other side of where line 50 crosses trajectory 44 an end of range line 56 can be drawn. The distance between the cross hair 40 and the top 42 of bottom post 38 can be correlated to equal the angle between lines 48 and 50 as determined by a graph such as FIG. 4. Conversely it can be decided a priori that the angle between lines 48 and 50 will be a set angle such as three minutes of angle. Thus, the length of double deviation lines 60 may or may not correlate with double the length of deviation line 58.
One might choose to set the angle between lines 48 and 50 to equal a value such as three minutes of angle because at 300 yards three minutes of angle will yield a deviation of approximately 9 inches. A normal deer'body from his shoulder to his brisket is approximately 18 inches. A shooter in looking through his rifle scope could then very easily estimate half of this distance to be approximately 9 inches.
The line 48 correlates with the line of sight through the rifle scope utilizing the primary sighting plane or cross hairs 40 of the reticle 34. The line 50 correlates with the line of sight through the rifle scope utilizing the secondary sighting plane across the top 42 of bottom post 38. Utilizing the example shown in FIG. 4 if the indicator mark 32 was aligned with the indexing mark 27 the shooter would be assured that he would be within the deviation distance equal to the line 58, i.e., about 41/2 inches for this figure whenever his target was within from zero yards to 280 yards. Further, beyond 280 yards up to approximately 335 yards he would know that his target was still within the deviation distance. Thus, a safe shot could be taken up to at least 280 yards and to somewhere beyond approaching 330 yards.
If the reticle 34 utilized in the rifle scope was set such that the cross hairs 40 deviated from top 42 of bottom post 38 by three minutes of angle the shooter would know that at 300 yards this distance would represent approximately 9 inches. If in viewing a target such as a deer the distance between the shoulder and the brisket of the deer was greater than half of the distance between the cross hairs 40 and the top 42 of the bottom post 38 the shooter would know that he was within 300 yards of the deer and would know that he was safe in using the primary sighting plane of the reticle 34 when the indicator mark 32 was aligned with the indexing mark 27. If in viewing the same deer as a target and half the distance between the shoulder and the brisket was less than the distance between the cross hairs 40 and the top 42 of bottom post 38 the shooter would know that he was at or beyond the cross-over point 54. At this point the shooter would then sight along the secondary plane of the reticle 34 the top 42 of bottom post 38 and he would be assured that he was within the deviation distance up to a point somewhere beyond 400 yards.
It can be seen that if the indicator mark 32 is aligned with the indexing mark 27 the shooter must make only one mental judgment before deciding whether to use the primary sighting plane or the secondary sighting plane. This mental judgment would simply be an estimation of the amount of inches of the target located between the cross hairs 40 and the top 42 of bottom post 38.
In variable power scopes of the type wherein the target'magnification is variable but the reticle'is not, one standard power must be chosen to use whenever a comparison using the cross hairs 40 and the top 42 of bottom post 38 is made. The actual distance between the cross hairs 40 and the top 42 of bottom post 38 is, of course, covered by the power chosen as the standard. | A trajectory compensating device for use with a rifle scope used in aiming a firearm is improved by including in the reticle of the rifle scope two sighting planes and including on the elevational turret of the rifle scope a turret cap which includes an indicia carrying member. The two sighting planes in the reticle are a primary sighting plane and a secondary sighting plane. The elevational turret of the rifle scope includes an indexing mark located thereon. The elevational turret controls the elevational correcting system of the rifle scope by rotation of the turret cap. The indicia carrying member includes at least two indicia markings. One of these indicia markings is correlated to correspond to a calibration distance wherein the rifle scope is sighted in utilizing the primary sighting plane of the reticle. The second of the indicia corresponds to an indicator mark which when lined up with the indexing mark will assure the shooter of the firearm that the trajectory of the bullet launched from the firearm will not deviate from either the line of sight across either the primary or the secondary sighting planes of the reticle by a fixed predetermined deviation distance from the trajectory of the bullet. | 5 |
RELATED APPLICATIONS
This is a division of application Ser. No. 363,443 filed May 24, 1973, now U.S. Pat. No. 3,907,827, issued Sept. 23, 1975, which is a divisional of application Ser. No. 74,519, filed Sept. 22, 1970, now U.S. Pat. No. 3,758,509, issued Sept. 11, 1973, which is a continuation-in-part of Ser. No. 11,023, filed Feb. 12, 1970, now U.S. Pat. No. 3,708,500, issued Jan. 2, 1973, which is a continuation-in-part of Ser. No. 824,319, filed May 13, 1969, now U.S. Pat. No. 3,544,600, issued Dec. 1, 1970 and a continuation-in-part of Ser. No. 825,389, filed May 16, 1969, now abandoned.
DETAILED DESCRIPTION OF THE INVENTION
This invention is concerned with certain polycyclic compounds and with processes for their synthesis. More particularly this invention relates to novel derivatives of cyclopenta[f][l]benzopyrans and 7H-naphtho[2,1-b]pyrans, amd to methods for their production. These compounds are useful as intermediates is syntheses of steroids and D-homosteroids, respectively. In syntheses of steroidal materials steric considerations are of great significance. The most used steroidal compounds are those having a C/D-trans ring junction with the substituent in the 13-position being in the β-stereoconfiguration. The present invention provides a facile total synthesis of 13β-C/D-transsteroidal materials. This desirable result is obtained via a unique asymmetric induction with optical specificity preserved in subsequent reaction steps. A particular aspect of this invention resides in the use of arylenedioxy ketals as protective groups for intermediate compounds in the synthesis of steroids. Arylenedioxy ketals exhibit unexpected advantages over other ketal protective groups, e.g., alkylenedioxy ketals in that the former groups are more stable to the reaction conditions employed in the synthesis thus providing substantially higher yields of desired end products. This is particularly true in the case of steps requiring oxidation in the presence of acid.
In a major aspect, this invention is concerned with novel derivatives of cyclopenta[f][1]benzopyrans having the tricyclic nucleus ##SPC1##
And novel derivatives of naphtho[2,1-b]pyrans having the tricyclic nucleus ##SPC2##
These novel compounds are generally defined by the formula: ##SPC3##
Wherein Y is ##EQU1## B is the remaining residue of an aryl group which may be monocyclic or bicyclic and which may bear one or more additional substituents selected from the group consisting of lower alkyl and lower alkoxy; R 1 is a primary alkyl group of from 1 to 5 carbon atoms; R 2 is hydrogen, lower primary alkyl, or lower acyl; R 5 , R 11 , R 12 , R 14 and R 15 are each independently hydrogen or lower alkyl; Z is carbonyl or a group of the formula ##EQU2## R 7 is hydrogen or lower acyl; R 8 is hydrogen or lower aliphatic hydrocarbyl; T represents either a single or a double bond; U represents a single or a double bond and is a single bond when T is a single bond; m is an integer having a value of 1 to 2; n is an integer having a value of from 0 to 1 and is 0 when T represents a double bond and is 1 when T represents a single bond; r is an integer having a value of from 0 to 1 and is 0 when T is a double bond and 1 when T is a single bond; and s is an integer having a value of from 0 to 1 and is 0 when U is a double bond and 1 when U is a single bond.
As used throughout the specification and appended claims, the term "hydrocarbyl group" denotes a monovalent substituent consisting solely of carbon and hydrogen; the term "hydrocarbylene" denotes a divalent substituent consisting solely of carbon and hydrogen and having its valence bonds from different carbons; the term "aliphatic", with reference to hydrocarbyl or hydrocarbylene groups, denotes groups containing no aromatic unsaturation, but which can be otherwise saturated or unsaturated, i.e., an alkyl or alkylene, or an aliphatic group containing olefinic or acetylenic unsaturation; the term "alkyl group" denotes a saturated hydrocarbyl group, whether straight or branched chain; the term "primary alkyl group" denotes an alkyl group having its valence bond from a carbon bonded to at least two hydrogens; the term "alkoxy" denotes the group R'O-, where R' is alkyl; the term "acyl group" denotes a group consisting of the residue of a hydrocarbyl monocarboxylic acid formed by removal of the hydroxyl portion of the carboxyl group; the term "oxyhydrocarbyl" denotes a monovalent saturated cyclic or acyclic group consisting of carbon, hydrogen, and oxygen containing only one oxygen in the form of an ether linkage; and the term "lower" as applied to any of the foregoing groups denotes a group having a carbon skeleton containing up to and including eight carbons, such as methyl, ethyl, butyl, tert.-butyl, hexyl, 2-ethylhexyl, vinyl butenyl, hexenyl, ethinyl, ethylene, methylene, formyl, acetyl, 2-phenylethyl, benzoyl, methoxymethyl, 1 -methoxyethyl, tetrahydropyran-2-yl, methoxy, ethoxy, and the like.
In the formulas presented herein the various substituents on cyclic compounds are joined to the cyclic nucleus by one of three notations, a solid line (--) indicating a substituent which is in the β-orientation (i.e., above the plane of the paper), a dotted line ( - - - - ) indicating a substituent which is in the α-orientation (below the plane of the paper), or a wavy line ( ) indicating a substituent which may be in either the α- or β-orientation. The position of R 1 has been arbitrarily indicated as the β-orientation, although the products obtained in the examples are all racemic compounds unless otherwise specified.
Preferred compounds are those wherein Y is 3,3-(arylenedioxy)butyl wherein the arylenedioxy group, when taken with the 3-carbon of the butyl radical, forms a dioxolane ring system, especially 3,3-(phenylenedioxy)-butyl, 3,3-(2,3-naphthalenedioxy)-butyl and 3,3-(4,5-dimethylphenylenedioxy)-butyl; R 1 is n-alkyl, especially methyl and ethyl; and, when s has a value of 1, the 9α- (when m is 1) or 10α- (when m is 2) hydrogen is transoriented with respect to R 1 .
Subgeneric to the tricyclic compounds of formula I are the 3-substituted 6aβ-alkyl-1,2,3,5,6,6a,7,8-octahydrocyclopenta[f][1]benzopyrans (by alternate nomenclature 3-substituted-6aβ-alkyl-2,3,5,6a,8-hexhydro-1H-cyclopenta[f][1]-benzopyrans) and the 3-substituted-6aβ-alkyl-1,2,5,6,6a,7,8,9-octahydro-3H-naphtho[2,1-b]pyrans (by alternate nomenclature 3-substituted-6aβ-alkyl-1,2,3,5,6,6a,8,9-octahydro-7H-naphtho[2,1-b]pyrans), hereinafter referred to as "dienes", having the formula: ##SPC4##
wherein R 1 , R 11 , Z, Y and m are as defined above; the 3-substituted-6aβ-alkyl-1,2,3,5,6,6a,7,9,9,9a-decahydrocyclopenta[f][1]benzopyrans (by alternate nomenclature 3-substituted-6aβ-alkyl,2,3,5,6,6a,8,9,9a-octahydro-1H-cyclopenta[f][1]benzopyrans) and the 3-substituted-6aβ-alkyl-1,2,5,6,6a,7,8,9,10,10a-decahydro-3H-naphtho[2,1-b]pyrans (by alternate nomenclature 3-substituted-6aβ-alkyl-1,2,3,5,6,6a,8,9,10,10a-decahydro-7H-naphtho[2,1-b]pyrans), hereinafter referred to as "monoenes" represented by the formula: ##SPC5##
wherein R 1 , R 11 , R 12 , Z, Y, and m are as defined above; and the 3-substituted-6aβ-alkyl-4a-hydroxyperhydrocyclopenta[f][1]benzopyrans and the 3-substituted-6aβ-alkyl-4a-hydroxyperhydro-3H-naphtho[2,1-b]pyrans and their lower alkyl ethers anmonoacyl esters, hereinafter referred to as "perhydro" compounds represented by the formula: ##SPC6##
wherein R 1 , R 2 , R 11 , R 12 , Z, Y and m are as defined above.
This invention is concerned with a method for producing the compounds of formula I via the following general reaction scheme: ##SPC7##
wherein Y, R 1 , R 2 , R 11 , R 12 , Z, and m are as defined above; and V is hydrogen, lower alkyl or lower acyl.
Thus, the process of this invention comprises the general steps of (1) condensation of a substituted 7-hydroxy-1-alken-3-one or a variant thereof (II), as defined below, with a 2-alkylcycloalkane-1,3-dione (III), as defined below, to produce diene (Ia); (2) saturation of the 9,9a- or 10,10a-double bond of diene (Ia) to produce monoene (Ib); and (3) introduction of a hydroxy, alkoxy, or acyloxy group at the 4a-position and a hydrogen atom at the 9b- or 10b-position of monene (Ib) to produce perhydro compound (Ic). It is to be understood that the foregoing reaction sequence is merely schematic in nature, and that each depicted step can represent only one or more than one reaction, as will be more fully described herein.
1-Alken-3-one compounds of formula II are employed as one of the starting materials for the foregoing reaction sequence. Illustrative examples of these 1-alken-3-ones include the 11,11-arylenedioxy-7-hydroxy-1-alken-3-ones, preferably 11,11-phenylenedioxy-7-hydroxy-1-dodecen-3-one.
The 11,11-arylenedioxy-7-hydroxy-1-dodecen-3-ones of formula II above or cyclic variations thereof are readily synthesized from 4,4-ethylenedioxy-1-chloropentane as per the following reaction sequence: ##SPC8##
where B is as above, C is alkylenedioxy, preferably ethylenedioxy or arylenedioxy, preferably phenylenedioxy, X is a halide, preferably chloride, R 16 is as hereinafter described and R 20 is lower alkyl.
As indicated in the above sequence in one embodiment 4,4-alkylene- or phenylenedioxy-1- chloropentane (a) is converted to the Grignard by treatment with magnesium metal. This reaction may be activated by the addition of a crystal of iodine to the reaction medium. The Grignard is then reacted with glutaraldehyde (b) to yield a hemiacetal (c). Conversion of this hemiacetal to formula II compounds may be accomplished by alternative routes. In a first route, where C is B, the hemiacetal (c) is reacted with vinyl Grignard in an ethereal solvent, e.g., tetrahydrofuran at -20° to 10°C. to yield the vinyl hydroxy compound (g). Treatment of (g) with manganese dioxide and R 16 H at room temperature in a hydrocarbon solvent yields compounds of formula II.
The hemiacetal (c) may also be oxidized utilizing a chemical oxidizing agent, e.g., silver nitrate, bromine, sodium dichromate bihydrate or potassium dichromate to yield the lactone (d). It is preferable that when the ketal moiety C is arylenedioxy that the oxidizing agent used be other than bromine due to the possibility of bromination of the aromatic ring. It is also possible to oxidize the hemiacetal (c) catalytically using oxygen and a noble metal catalyst, e.g., platinum black. Where C is arylenedioxy in lactone (d), the lactone may be converted directly to compounds of formula II by reaction with vinyl Grignard in ethereal solvent, e.g., tetrahydrofuran at temperatures below 0°, preferably -70°C. to -45°C.
Where C in lactone (d) is alkylenedioxy, the lactone is treated with aqueous acid to hydrolyze the ketal group to form the keto lactone (e). Treatment of the keto lactone with the desired dihydroxy aryl compound such as, for example, catechol, 4,5-dimethylcatechol or a 1,2 or 2,3-naphthdiol, preferably in an inert organic solvent, e.g., an aromatic hydrocarbon such as benzene, toluene or xylene, preferably benzene under conventional conditions, e.g., at reflux.
The aforesaid ketalization reaction may produce a ketal half-ester as an intermediate which is readily convertible into the desired arylenedioxy lactone upon distillation.
Compounds of formula II are then obtained from said arylenedioxy lactones (f) by the selective addition of vinyl Grignard, e.g., vinyl magnesium chloride to the lactone at low temperatures, e.g., below 0°C., most preferably at about -45°C. in an inert organic solvent medium such as an etheric solvent, preferably diethyl ether, diisopropyl ether, tetrahydrofuran, dioxane or the like.
In an alternative procedure, ketal lactones of formula d wherein C is B may be conveniently prepared from the arylenedioxyketal (h) by reaction with a 5-oxo-pentanoic acid ester, e.g., the ethyl ester at a temperature of about -60°C. to -30°C. in tetrahydrofuran.
Because of the susceptibility of the vinyl group of the 7-hydroxy-1-alken-3-one to decomposition, it is desirable, although not essential, that this compound be converted to more stable variants, such as those of the formula: ##EQU3## wherein R 11 , R 12 , Y and V are as defined above; and R 16 is chloro, hydroxy, lower alkoxy, lower hydrocarbylamino or di(lower hydrocarbyl)amino. rocarbyl)amino.
As exemplary, these compounds of formula II-a are readily produced from the vinyl ketones of formula II by known techniques. For example, 1-chloro-7-hydroxyalkan-3-ones are obtained by the anti-Markownikoff reaction of the vinyl compound with hydrogen chloride in known manner. 1-Hydroxy and 1-alkoxy derivatives are obtained by the base-catalyzed reaction of water or a lower alkanol, for example, methanol, with the vinyl ketone. Additional derivatives are formed by the reaction of the vinyl ketone with a mono(lower hydrocarbyl)- or di(lower hydrocarbyl)-amine to form the Mannich base 1-(lower hydrocarbyl)amino- or 1-di(lower hydrocarbyl)amino-7-hydroxyalkan-3-one. A particularly advantageous procedure is to oxidize a hydroxy vinyl compound e.g. formula (g) with manganese dioxide in the presence of such an amine. In some instances, particularly in large scale commercial operation, it may be desirable to convert the Mannich base to its crystalline acid addition salts, particularly quaternary ammonium salts. All of the chloro, hydroxy, alkoxy, and aminoalkanones yield the alkenones of formula II under the conditions of the condensation with the 2-alkylcycloalkane-1,3-dione.
The compounds of formula II as is evident from the previously described reaction sequence can be used in the form of still another variant. This is the cyclized variant comprising a cyclic hemiketal, i.e., 2-tetrahydropyranol of the formula: ##SPC9##
wherein Y is as defined above and R 17 is lower hydrocarbylamino or di(lower hydrocarbyl)amino. The variants of formula IIb can be prepared from compounds of formula II by reaction with the same reactants as are used to produce those compounds of formula IIa wherein R 16 is lower hydrocarbylamino or di(lower hydrocarbyl)amino. As is apparent, those compounds of formula IIa wherein R 16 has the aforesaid meanings and the compounds of formula IIb are isomers. These isomers exist in the form of a ketone of formula IIa or in the form of the cyclic hemiketal of formula IIb or as an equilibrium mixture of the two forms. Whether a particular Mannich base of formula IIa exists in that form or the hemiketal form or in an equilibrium mixture consisting primarily of one or the other will depend upon the environmental conditions in which it is placed, such as temperature, solvent, and pH of reaction medium, as well as the particular meaning of Y and R 16 or R 17 . Either form is useful for the purposes of this invention since these isomers are used in a reaction with compounds of formula III, infra, and either the acylic form of formula IIa or the cyclic hemiketal form of formula IIb is useful for this purpose. A particular advantage of the cyclic form is its greater stability as compared with the acyclic form and also as compared with the vinyl ketones of formula II. In order to obtain the cyclic form it is essential that in the compound of formula IIa, V is hydrogen. Acidic conditions shift the equilibrium away from the cyclic form. Use of an optically active amine, e.g., α-phenylethylamine, offers the advantage of resolving the compound, for example, via salt formation, e.g., the oxalate salt, to give an optically pure isomer of formula IIa or IIb which is then used either in the form of the free base, as the salt or as a lower alkanol adduct, e.g., methanol adduct in the remainder of the reaction sequence of this invention and when coupled with the unique asymmetric induction and preservation of optical specificity thereof offers a facile route to optically pure steroidal materials.
As is indicated above, the 7-hydroxy group of the 7-hydroxydodecanone of formula II or IIa can be esterified or etherified for the condensation reaction with the cycloalkanedione. These reactions can be effected in known manner. For example, the 7-hydroxyalkan-3-one can be reacted with a carboxylic acid or an acid chloride to produce an ester, or can be converted to an ethe by either (1) preferably, known acid catalyzed etherifications, e.g., with isobutylene or dihydropyran or (2) conversion of the 7-hydroxyalken-3-one to its sodium salt followed by reaction of the salt with an alkyl halide. In the event R 8 is hydrogen, this hydroxyl group is also etherified or esterified.
The starting material of formula II or variant thereof can either be used in racemic form or in optically active form. Where used in optically active form, the 7S- antipode is preferred for reasons more fully explained below.
The second reactant employed in the condensation as generally mentioned above is a 2-(lower alkyl)cycloalkane-1,3-dione of the formula: ##SPC10##
wherein R 1 and m are as defined above. These compounds are known compounds and decription of their synthesis is accordingly unnecessary. Suitable compounds include 2-methylcyclopentane-1,3-dione, 2-ethylcyclopentane-1,3-dione, 2-propylcyclopentane-1,3-dione, 2-butylcyclopentane-1,3-dione, 2-methylcyclohexane-1,3-dione, and the like.
The conditions for the condensation of ketone (II) or variant (IIa or IIb) with cyclic dione (III) are not narrowly critical, although it is preferred, particularly when the acyclic ketone is charged as the vinyl ketone, that a non-oxidizing atmosphere, e.g., nitrogen or argon, be employed. It is further preferred that an antioxidant, for example, phenolic compounds such as hydroquinone, be present. Furthermore, the reaction can be conducted in the absence or presence of acid or base promoters. Suitable basic promoters include those heretofore known to promote the Michael condensation, including inorganic bases, for example, alkali metal hydroxides, such as sodium hydroxide or potassium hydroxide, and organic bases, including alkali metal alkoxides, for example, sodium or potassium methoxide or ethoxide, and ammonium hydroxides, particularly benzyltrialkylammonium hydroxide. A preferred class of base promoters are the amines, especially tertiary amines and most preferably pyridine-type compounds such as pyridine and the picolines. Acid promoters which can be employed include organic carboxylic acids such as acetic acid or benzoic acid; organic sulfonic acids such as p-toluenesulfonic acid; and mineral acids such as sulfuric acid, phosphoric acid, hydrochloric acid, and the like. The amount of promoter employed is not narrowly critical and can vary from catalytic amounts to molar amounts.
The ratio of ketone (II) or variant (IIa or IIb) to cyclic dione (III) is not narrowly critical, although approximately equimolar amounts are preferred. Although there is no particular advantage to the use of excesses of either reactant, the cycloalkanedione can be more readily employed in excess because, due to its general low solubility in known organic solvents, unreacted cycloalkanedione can be easily recovered from the reaction mixture.
The reaction temperature is not critical and can vary from room temperature or below to reflux temperature or higher. The condensation is preferably conducted in the presence of an inert solvent to insure a fluid reaction mixture and uniform reaction temperatures. Suitable solvents include tertiary alcohols such as tert.-butanol; aliphatic and aromatic hydrocarbons such as cyclohexane, hexane, octane, benzene, xylene, toluene, and the like; ethers such as diethyl ether, tetrahydrofuran, and the like; chlorinated hydrocarbons such as carbon tetrachloride, chloroform, and the like; as well as dipolar aprotic solvents such as dimethyl sulfoxide and the N,N-disubstituted amides such as dimethylformamide or dimethylacetamide.
The product of the condensation, depending upon the nature of vinyl ketone or variant (II, IIa or IIb) and/or the reaction promoter employed, can be one or more of the compounds having the formulae: ##SPC11##
wherein R 1 , R 11 , R 12 , V, Y, and m are as defined above.
When vinyl ketone (II) is a 7-alkoxy- or 7-acyloxy compound, the product will be a compound of formula IV. However, when the vinyl ketone is a 7-hydroxy compound, or the reaction conditions are sufficient to convert a 7-alkoxy- or 7-acyloxy group, if present, the product will depend upon the promoter.
When the promoter is an acid or a relatively weak base, such as pyridine, or when no promoter is employed at all, the reaction product obtained from the 7-hydroxy vinyl ketone is the diene, i.e., tricyclic enol ether (Ia-1). When a strong base, such as sodium or potassium hydroxide, is employed as a promoter, a crystalline product having the formula VI is isolated, although compounds of formulae IV and V are also present in the reaction mixture. However, the compounds of formulae IV, V and VI, upon treatment with an acid, such as acetic acid, para-toluenesulfonic acid, or sulfuric acid, readily form the diene, i.e., tricyclic enol ether (Ia-1). It should also be noted that the conversion of the acyloxy or alkoxy groups of compound (IV) to a hydroxy group in an acidic medium is accompanied by cyclization to enol ether (Ia-1).
The condensation of a vinyl ketone of formula II or a variant thereof of formula IIa or IIb with a cycloalkanedione of formula III is one of the key features of this reaction. It is in this condensation that specific stereochemical induction at one member of the critical C/D-ring junction of the eventual steroidal product occurs. Thus, this invention is particularly advantageous in that it involves a unique asymmetric induction. Thus, the products of the condensation, i.e., the dienones of formula Ia-1, have at least two asymmetric centers at positions 3 and 6a permitting theoretically of two racemates or four optical antipodes. However, as a result of the condensation of this invention, when using a racemic starting material of formulas II, IIa or IIb wherein R 11 and R 12 are both hydrogen only a single racemate of formula Ia-1 results and when using an optically active starting material of formulas II, IIa or IIb wherein R 11 and R 12 are both hydrogen only a single optical antipode of formula Ia-1 results. It has further been found that when starting with a compound of formula II or IIa with a 7S-stereoconfiguration or of formula IIb with corresponding stereoconfiguration there is obtained the more desirable optical antipode of formula Ia-1 having a 6aβ-stereoconfiguration. Thus, to prepare steroidal materials having the more desired 13β-stereoconfiguration by the synthesis of this invention one can either start with the antipode of formula II, IIa or IIb, which can be prepared by resolving a racemic compound of formula II, IIa or IIb, or one can resolve at some intermediate stage subsequent to the condensation with a cycloalkanedione of formula III or one can resolve the end-product steroidal material. In any event, the unique asymmetric induction concurrent to the condensation of this invention renders the obtention of a single optical antipode as an end-product more facile. The simultaneous formation of the dienol ether of formula Ia-1 with unique asymmetric induction is a special advantage of this invention.
The dienes of formula Ia in the presence of water and acid, e.g., sulfuric acid in acetone, aqueous acetic acid or aqueous hydrochloric acid in dioxane, undergo acid hydrolysis to form indenones of the formula ##SPC12##
wherein R 1 , R 11 , R 12 , Y and m have the same meaning as above. The indenones of formula Ia' are themselves convertible to compounds of formula Ia via dehydration, for example, via acid catalyzed azeotropic distillation in benzene. Suitable acid catalysts are p-toluenesulfonic acid, potassium bisulfate, boron trifluoride etherate and the like. This reversible hydrolysis of compounds of formula Ia is useful in their preparation and purification. Thus, in instances where the direct purification of compounds of formula Ia is difficult it is often more facile to hydrolyze the compound of formula Ia to a compound of formula Ia' which can then be purified, for example, by chromatography, and subsequently be reconverted to the desired compound of formula Ia via dehydration.
The ketodienes of formula Ia-1 are readily converted to the corresponding 7β-alcohols and their esters as represented by the formula: ##SPC13##
wherein Y, R 1 , R 7 , R 11 , R 12 and m are as previously defined, by the sequence of reactions comprising reduction of the ketone to the alcohol and, if desired, subsequent esterification.
The reduction can be effected by any of the known methods for the chemical reduction of a ketone, e.g., by reaction of dienone (Ia-1) with an alkali metal or Group III-metal reducing agent. By the term "alkali metal," as employed herein, is meant a Group I-metal having an atomic number of from 3 to 19, inclusive, i.e., lithium, sodium, and potassium. Group III-metals include those having atomic numbers of from 5 to 13, inclusive, i.e., boron and aluminum. Illustrative examples of these reducing agents include an alkali metal, preferably lithium or sodium, in liquid ammonia or a liquid aliphatic amine, tri(lower alkoxy)-aluminum compounds such as triisopropoxyaluminum; di(lower alkyl)-aluminum hydrides such as diethylaluminum hydride and diisobutyl-aluminum hydride; alkali metal-Group III-metal complex hydrides such as lithium aluminum hydride, sodium aluminum hydride, and sodium borohydride; tri(lower alkoxy)alkali metal-Group III-metal complex hydrides such as trimethoxy lithium aluminum hydride and tributoxy lithium aluminum hydride; diisobutyl aluminum hydride and the like. The alkali metal-Group III-metal complex hydrides are preferred as reducing agents, with the nonalkaline reagents, such as lithium aluminum hydride, being especially preferred.
This reaction is effected in any suitable inert reaction medium, such as hydrocarbons, e.g., cyclohexane, benzene, toluene, and xylene; ethers, e.g., diethyl ether, diisopropyl ether, and tetrahydrofuran. Protic solvents, such as water or alcohols, should not be employed when lithium aluminum hydride is the reducing agent, but can be employed with sodium borohydride.
The remaining reaction conditions are not narrowly critical, although it is generally preferred to effect the reduction at reduced temperatures, i.e., below about room temperature (about 20°-25°C.). Temperatures in the range of from about 0°C. to about room temperature are normally employed.
The free alcohol is recovered from the reaction mixture after treatment of the mixture with acid. The alcohol can be esterified in known manner, for example, by base-catalyzed reaction with a carboxylic acid halide or carboxylic acid anhydride. Illustrative bases include inorganic bases such as sodium hydroxide and potassium hydroxide and organic bases such as a sodium alkox or an amine, especially a tertiary amine, and more particularly, pyridine and the picolines.
The ketodienes of formula Ia-1 can also be converted to their 7β-hydroxy-7α-hydrocarbyl derivatives represented by the formula: ##SPC14##
wherein Y, R 1 , R 6 , R 11 , R 12 and m are as previously defined and R 13 is lower hydrocarbyl by reaction of the ketodiene with a Grignard reagent of the formula:
R.sub.13 MgX VII
wherein R 13 is as previously defined and X is a halogen having an atomic number of from 17 to 35, inclusive (i.e., chlorine or bromine).
This Grignard reaction is conducted in known manner. For example, the Grignard reagent is prepared by reacting a hydrocarbyl halide with magnesium in an ether reaction medium, for example, ethyl ether or tetrahydrofuran, at elevated temperature, generally in the range of from about 40°C. to about 75°C. The ketodiene (Ia-1) is then added to the Grignard solution at about room temperature, although higher or lower temperatures can be employed. The resulting reaction product is hydrolyzed to produce the free alcohol, which can be esterified as discussed above.
Alternatively, the alcohols can be prepared by reaction of ketodiene (Ia-1) with a hydrocarbyl alkali metal compound such as methyl lithium, sodium acetylide, potassium acetylide, and the like.
The second step of the general synthesis of the tricyclic compounds of this invention comprises conversion of the dienes of formula Ia to the monoenes of formula Ib by catalytic hydrogeneration. Suitable catalysts include the noble metals, such as platinum, palladium, rhodium, and the like, as well as Raney nickel and other hydrogenation catalysts. These catalysts can be employed in the form of the metal alone, or can be deposited on suitable support materials, such as carbon, alumina, calcium carbonate, barium sulfate, and the like. Palladium and rhodium are preferred as catalysts. The hydrogenation is preferably conducted in the presence of inert solvents such as hydrocarbons, alcohols, ethers, and the like. The reaction conditions of pressure and temperature are not narrowly critical, and normally a hydrogen pressure of about one atmosphere and a temperature of about room temperature are employed. These ambient conditions are generally preferred to avoid significant hydrogenation of the 4a,9b(10b)-double bond, although more severe conditions, for example, up to about 100°C. and up to about 100 atmospheres, can be employed if desired. The hydrogenation medium can be acidic, neutral, or basic, as may be desired, although neutral media, such as hydrocarbons, e.g., toluene or hexane, or basic media, such as an alcohol-base, e.g., methanol-sodium hydroxide, mixture are preferred for best results. In general, hydrogenation of the diene of formula Ia leads to the corresponding monoene of formula Ib. However, in the event R 8 is an unsaturated hydrocarbyl radical, the hydrogenation, in addition to hydrogenating the ring double bond, also hydrogenates the 7α-hydrocarbyl substituent, converting it to an alkyl group.
Via the aforesaid catalytic hydrogenation C/D-trans compounds are formed in a major proportion when hydrogenating a diene of formula Ia-2. This method thus provides an advantageous synthesis of C/D-trans steroidal materials. When hydrogenating a diene of formula Ia-1, C/D-cis compounds are formed in a major proportion. This method thus provides an advantageous synthesis of C/D-cis steroidal materials.
Compounds wherein Z is carbonyl, as represented by the formula: ##SPC15##
wherein Y, R 1 , R 11 , R 12 and m are as previously defined, can be converted to the corresponding alcohols or esters of the formula: ##SPC16##
wherein Y, R 1 , R 7 , R 11 , R 12 and m are as previously defined, or to the 7β-hydroxy-7α-hydrocarbyl compounds of the formula: ##SPC17##
wherein Y, R 1 , R 7 , R 11 , R 12 , R 13 and m are as previously defined, by the techniques discussed above regarding the dienes of formula Ia.
When Z is carbonyl and the hydrogenation is effected under basic conditions, there is a tendency toward the production of predominantly the 6a/9a(10a)-cis-compound; that is, the hydrogen atom in the 9a(10a)-position of formula Ib-1 is predominantly in the β-orientation. When these compounds are intended as intermediates for the synthesis of steroids having the C/D-trans-orientation, this technique is not particularly desirable. Although the ratio of β- to α-orientation falls to about 1:1 at neutral conditions when hydrogenating a compound wherein Z is carbonyl, it is preferred to hydrogenate a 7β-alcohol or ester of formula Ia-2 because the products of his hydrogenation are predominantly the 6a/9a(10a)-trans-compounds. Compounds of formula Ia-3 when subjected to the hydrogenation yield a ratio of β- to α-orientation in between that of the compounds of formula Ia-1 and that of the compounds of formula Ia-2. When monoenes of formula Ib-1 having C/D-trans configuration are desired, it is preferable to first reduce the dienone of formula Ia-1 to a corresponding hydroxy compound of formula Ia-2 prior to the catalytic hydrogenation. Following the catalytic hydrogenation the carbonyl moiety in formula Ib-1 can be regenerated by conventional means, such as oxidation with CrO 3 .
The monoene compounds of formula Ib prepared by the above-described hydrogenation contain at least three asymmetric center at positions 3, 6a and 9a when m is one and at positons 3, 6a and 10a when m is two. With respect to these three centers there are thus eight antipodal configurations possible. By virtue of the unique asymmetric induction of this invention, proceeding from a racemic starting material of formula II, IIa or IIb only four of these antipodes of formula Ib are prepared and proceeding from an optically active starting material of formula II, IIa or IIb only two of these antipodes of formula Ib are prepared. Moreover, by the above-described hydrogenation of this invention and by appropriate selection of the 7-substituent in the diene of formula Ia subjected to the hydrogenation there can predominantly be prepared the desired 6a,9a(10a)-trans-stereo configuration. Thus, the eventual obtention of the more desired 13β-C/D-trans-configuration in the ultimate steroidal products is rendered more facile by the stereoselective reactions provided by this invention.
The final reaction of applicant's general process for the compounds of this invention is the conversion of the monoene of formula Ib to the perhydro compound of formula Ic by reaction of the monoene with a compound having the formula:
R.sub.2 OH VIII
wherein R 2 is as previously defined. That is, the monoene of formula Ib is reacted with water, a primary alcohol, or a carboxylic acid. This reaction is catalyzed by mineral or organic acids, for example, hydrochloric acid, phosphoric acid, sulfuric acid, para-toluenesulfonic acid, and the like. Sulfuric acid is the preferred acid catalyst, and water the preferred reactant. Although not necessary, it is desirable to conduct this reaction in the presence of an added solvent, particularly in the event the compound of formula VIII is water. In this case, it is desirable to employ a solvent which is both miscible with water and a solvent for the monoene of formula Ib. Solvents of this nature include acetone, tert,- butanol, dioxane, and the like. The reaction temperature is not critical, and ambient temperature is normally employed, although higher and lower temperatures could be employed if desired.
As with the compounds of formulae Ia-1 and Ib-1, the compounds of general formula Ic wherein Z is carbonyl: ##SPC18##
wherein Y, R 1 , R 2 , R 11 , R 12 and m are as previously defined are readily converted to their corresponding alcohols: ##SPC19##
wherein Y, R 1 , R 2 , R 7 , R 11 , R 12 and m are as previously defined, or the β-hydroxy-α-hydrocarbyl compounds: ##SPC20##
wherein Y, R 1 , R 2 , R 6 , R 11 , R 13 and m are as previously defined, by the previously described methods. .
In a modification of the general technique outlined above, one can simultaneously effect the hydrogenation and hydration steps, for example, by hydrogenation of a diene of formula Ia in aqueous sulfuric acid. When this simultaneous hydrogenationhydroation reaction is effected, it is preferred to begin with a diene having a hydroxyl group in the 7β-position.
As indicated above, the tricyclic compounds which form part of the present invention are useful as intermediates for the preparation of various steroid compounds, particularly 19-norsteroids of the normal series, as illustrated by the following reaction scheme. ##SPC21##
wherein R 1 , R 11 , R 12 , R 14 , R 15 , Y, Z and m are as above.
In the first step of this reaction scheme, the compound of formula Ic is oxidized to form bicyclic compound of the formula X by contact with such oxidizing agents as chromic acid, potassium dichromate, or potassium permanganate. Jones reagent (chromic acid, sulfuric acid and acetone), or a chromic acid-acetic acid mixture are preferred as oxidizing agents. The nature of Z is unchanged in this reaction, except when Z is hydroxymethylene [--CH(OH)--]. In this instance, unless the hydroxyl group is protected, as by formation of a lower acyl ester, it is oxidized to form a carbonyl group. A hydroxylated product is readily obtained, however, by hydrolysis of a product ester. The reaction temperature is not narrowly critical, and temperatures in the range of from 0°C. to about 75°C. are suitable, although ambient temperatures are preferred.
In the second step, bicyclic compound (X) is treated with acid or base to effect cyclization to (XI). In this reaction, it is preferred that the water of reaction be removed, as by refluxing the reaction mixture with an azeotroping agent in the presence of a strong acid and separating the water from the condensate. Suitable strong acids are sulfuric acid, p-toluenesulfonic acid, potassium bisulfate and the like. Alternatively, base catalyzed dehydration can be utilized, for example, by refluxing compound (X) in the presence of methanolic sodium hydroxide.
The hydrogenation of cyclo-olefin XI is preferably effected with a noble metal catalyst, e.g., a palladium-charcoal catalyst or a rhodium catalyst. Mild conditions are generally employed, e.g., room temperature and atmospheric pressure are convenient conditons for this reaction. The hydrogenated compound of formula XIa is converted to the desired 19-nor-steroid of formula XII by heating it, preferably at reflux, with dilute aqueous acid, preferably a mineral acid such as hydrochloric acid in a lower alkanol solvent medium, preferably methanol.
Compounds of formula XI wherein Z is carbonyl can be converted into corresponding pregnane compounds i.e., compounds in which Z is of the formula ##EQU4## by known procedures. Thus, for example, 19-nor-14β-androst-4-ene-3,17-dione can be converted into 19-nor-14β,17α-progesterone. These procedures for converting androst-17-ones into pregnanes are best effected if all carbonyl groups other than that in the 17-position are initially protected.
As has been pointed out above, the products of this invention are produced in the form of various optically active antipodes which can be carried through the entire reaction sequence, or which can be resolved at suitable places during the reaction sequence. For example, at any stage wherein a compound having a secondary hydroxyl group is present, such as hydroxytetrahydropyran (IV), or any of the hydroxy compounds of formula I, one can react the secondary alcohol with a dicarboxylic acid to form a half-ester. Suitable dicarboxylic acids include lower alkyl dicarboxylic acids such as oxalic acid, malonic acid, succinic acid, glutamic acid, adipic acid, or aromatic carboxylic acids such as phthalic acid. The resulting half-ester is then reacted with an optically active base, such as brucine, ephedrine, or quinine, to produce a diastereomeric salt. The salts, after separation, are then readily reconverted to optically active alcohols. As an alternative, the secondary alcohol can be reacted with an optically active acid, for example, camphorsulfonic acid. The resulting diastereomeric esters are then separated and reconverted to the alcohols.
It is preferred that the resolution be effected at some stage in the synthesis of alken-3-one, as by the above-mentioned resolution of hydroxytetrahydropyran (IV). In a more preferred technique optically active 5-alkyl-5-valerolactone is obtained from 5-alkyl- 5-oxopentanoic acid via known microbiological processes. The S-form of this lactone is the preferred form for use in accordance with this invention. In a third method, the racemic lactone can be hydrolyzed to the corresponding hydroxy acid, which is then resolved by treatment with an optically active base in the manner described above. Still other methods will be apparent to those skilled in the art. Resolution at such early stages in the overall process described herein is highly preferred because of the improved efficiency in the production of steroids having a desired stereo-configuration. Because the stereo-configuration is retained throughout the synthesis of alken-3-one (II), and further because the condensation of alken-3-one or variant (II, IIa or III) with cycloalkanedione (III) is stereo-specific, one, by proper selection of stereo-isomers at these early stages, can ensure that substantially all of the tricyclic compounds of this invention and the steroids derived therefrom have a selected stereo-configuration. Thus, by this technique, the production of compounds of the undesired configuration is minimized or prevented entirely, with an attendant increase in the efficiency of the production of compounds of the desired configuration.
In the claims, all compounds shall be construed to include, independently, the racemic form of the compound and independently, each enantiomeric form, i.e., the d and l configurations unless specifically indicated otherwise.
The following examples are illustrative. All temperatures are in degree Centigrade and all products having centers of asymmetry are racemic unless specifically indicated otherwise.
Example 1
(±)-9,9-Ethylenedioxy-5-hydroxy-decanoic acid lactone
25 G. of the hemiacetal, (±)-6-[3-(2-methyl-1,3-dioxolan-2-yl)propyl] tetrahydropyran-2-ol was dissolved in a mixture of dimethylformamide (DMF) acetic acid- water-sodium acetate (anhydrous) (250 ml; 120 ml. H 2 O/120 ml DMF/40 ml AcOH/24 g. NaOAc). Bromine (7 ml.) was then added to the cold (5°-10°) solution over 2-5 min. and the mixture was then stirred for a further 45 min. at room temperature. Aqueous sodium bisulphite solution and brine were then added and the organic products were isolated with benzene (5 × 125 ml.). The benzene extracts were washed with saturated brine solution (5 × 50 ml.) and then taken to dryness in vacuo. The crude lactone, (±)-9,9-ethylenedioxy-5-hydroxy-decanoic acid lactone yielded pure material on distillation bp 138-140/.02 mm.
In another experiment the hemiacetal, (±)-6-[3-(2-methyl-1,3-dioxolan-2-yl)propyl] tetrahydropyran-2-ol gave the lactone, (±)-9,9-ethylenedioxy-5-hydroxy-decanoic acid lactone, b.p. 141°-145°/.3 mm.
The starting material may be prepared as follows:
A solution of 2,2-ethylenedioxy-5-chloropentane in tetrahydrofuran (THF) (50 ml; 164 g. in 1600 ml. THF) was added to magnesium (38 g.) activated with a crystal of iodine. This mixture was stirred and heated at reflux until the reaction commenced. The rest of the chloroketal solution was then added over approximately 1 hr. to sustain gentle reflux. After complete addition, the mixture was stirred at room temperature for a further 2 hr.
A solution of freshly distilled glutaraldehyde (110 g.) in THF (1000 ml.) cooled to -40° was treated with the above Grignard reagent (as rapidly as possible) and then stirred 30 min at -30° and a further 1 hr. at 0°. Aqueous ammonia chloride solution (300 ml; 25 percent) was then added and the products were isolated with ether. Removal of the solvents in vacuo gave the product as a mobile liquid (185 g.). This material was stirred at 50° with aqueous sodium sulfite solution (1500 ml; 20 percent) and the pH was adjusted first to pH 6.5 with acetic acid and then pH 7.5 with sodium hydroxide solution (20 percent). The aqueous phase after stirring for 1 hr. at 50° was extracted with ether and then treated with caustic soda solution (20 percent) to pH 12. Extraction with benzene then furnished the hemiacetal (±)-6-[3-(2 -methyl-1,3-dioxolan-2-yl)-propyl]tetrahydropyran-2-ol (118 g.) as a mobile, pale yellow liquid. A sample was distilled (molecular still) to give a colorless product, b.p. 130°-132°/.1 mm.
Example 2
(±)-9-Oxo-5-hydroxydecanoic acid lactone
52.4 G. of the ketal lactone, (±)-9,9-ethylenedioxy-5-hydroxy-decanoic acid lactone dissolved in acetone (150 ml.) was treated with water (75 ml.), dilute aqueous sulphuric acid (2N; 45 ml.) and left to stand at room temperatue for 16 hr. Addition of brine and extraction with benzene gave the crude lactone, (±)-9-oxo-5-hydroxydecanoic acid lactone which on distillation yielded pure material >98 percent pure by vpc bp 134°/.05 mm.
Example 3
(±)-9,9-Phenylenedioxy-5-hydroxy-decanoic acid lactone
15 G of a solution of the ketolactone (±)-9-oxo-5-hydroxy-decanoic acid lactone in benzene (300 ml.) was treated with 20 g. catechol and 0.6 g. p-toluenesulphonic acid (PTS). The mixture was heated at reflux under nitrogen in conjunction with a soxhlet extraction apparatus equipped with a thimble filled with calcium hydride. After 18 hr. at reflux the mixture was cooled and chromatographed directly on silica gel (0.2-0.5 mm mesh; 650 g.). Elution with 5%, 10% and 15% ethyl acetate-benzene mixtures yielded the ketal ester.
Distillation of the above material gave catechol and the desired lactone, (±)-9,9-phenylenedioxy-5-hydroxy-decanoic acid lactone, bp 152°-170°/.2 mm. (This was a short path distillation and the majority of the material had bp 157°-162°). A sample of this material was redistilled (Kugel Rhor) and gave material, bp 140°-54°/.02 mm.
Example 4
(±)-6-(4,4-Phenylenedioxypentyl)-2-(2-diethylaminoethyl)-tetrahydropyran-2-ol
1.6 G. of the ketal lactone, (±)-9,9-phenylenedioxy-5-hydroxy decanoic acid lactone in tetrahydrofuran (THF; 15 ml.) was cooled to -45° and treated over 5 min. with a solution of vinyl magnesium chloride in THF (4.6 ml; 2 mol/liter). After stirring a further 25 min. at -45°, methanol (5ml) was added followed by an aqueous ammonium chloride solution (15 percent; 20 ml.). The products were extracted into ether and the ether extracts then treated with diethylamine (5 ml.) and dried over magnesium sulphate. Removal of the solvents in vacuo gave the crude Mannich base which was separated from neutral material with dilute aqueous acid (1N.H 2 SO 4 ; 4 × 15 ml.). The aqueous extracts were made basic with caustic potash solution and the products isolated with ether. Removal of the solvents in vacuo gave the Mannich base, (±)-6-(4,4-phenylenedioxypentyl)-2-(2-diethylaminoethyl)-tetrahydropyran-2-ol as a mobile liquid.
This material showed one spot on tlc analysis on development with a benzene/triethylamine (9:1) system.
Example 5
(±) -3-(4,4-Phenylenedioxypentyl)-6a,β -methyl-1,2,3,5,6,6a -hexahydrocyclopenta[f][1]benzopyran-7(8H)-one
10.6 G. of the Mannich base, (±)-6-(4,4-phenylenedioxypentyl2-(2-diethylaminoethyl)-tetrahydropyran-2-ol in toluene (80 ml.) was added rapidly to a refluxing solution of 2-methylcyclopentan-1,3-dione (4.7 g.) in toluene (50 ml.), acetic acid (23.2 ml.) and pyridine (7.2 ml.) under nitrogen. After heating at reflux for a total of 4 hr. (reaction followed by tlc) the mixture was cooled, diluted with toluene (100 ml.) and extracted with water (4 × 50 ml.), saturated aqueous sodium bicarbonate solution (1 × 50 ml.), brine (1 × 50 ml.) and dried over MgSO 4 . Removal of the solvents in vacuo yielded the crude crystalline dienolether, (±)-3-(4,4-phenylenedioxypentyl6a,β -methyl-1,2,3,5,6,a-hexahydrocyclopenta[f][1]benzopyran-7(8H)one, m.p. 115°-120°. A sample of this material was recrystallized from benzene-hexane mixture to give pure material mp 126°-129°.
Example 6
(±)-3-(4,4-Phenylenedioxypentyl)-6a,β-methyl-1,2,3,5,6,6a,7,8-octahydrocyclopenta[f][1]benzopyran-7β-ol
10.7 G. of the crude dienolether, (±)-3-(4,4-phenylenedioxypentyl)-6a,β-methyl-1,2,3,5,6,6a-hexahydrocyclopenta[f][1]benzopyran-7(8H)-one dissolved in THF/ether (100 ml; 1:1) was added to a slurry of lithium aluminum hydride (4 g.) in a THF/ether mixture (400 ml; 1:1) cooled in an ice-salt bath (temp. held at ˜3°). After complete addition the mixture was stirred for a further 10 min. at -5° and 13/4 hr. at room temperature (followed by tlc). Wet ether (100 ml.) was then added followed by a saturated aqueous solution of sodium sulphate (25 ml.). The coagulate salts were then filtered off, washed with THF and the filtrate was dried over MgSO. Removal of the solvents in vacuo gave the crude alcohol, (±)-3-(4,4-phenylenedioxypentyl)-6a,β-methyl-1,2,3,5,6,6a,7,8-octahydrocyclopenta[f][1]benzopyran-7β-ol
Example 7
(±)-3-(4,4-Phenylenedioxypentyl)-6a,β-methyl-1,2,3,5,6,6a,7,8,9,9a-decahydrocyclopenta[f][1]benzopyran-7β-ol
11.2 G. of the crude dienolether alcohol, (±)-3-(4,4-phenylenedioxypentyl)-6a,β-methyl-1,2,3,5,6,6a,7,8-octahydrocyclopenta[f][1]benzopyran-7β-ol (this still contains some solvent) was dissolved in toluene (100 ml.) treated with 2 g. of a 5% Pd/C catalyst and hydrogenated at room temperature and prssure. After 51/2 hr. the uptake of hydrogen stopped (635 ml; theory 700 ml. at room temperature and pressure for 10.7 g.) and the solids were filtered off and washed with toluene. Removal of the solvents in vacuo gave the enol ether, (±)-3-(4,4-phenylenedioxypentyl)-6a,β-methyl-1,2,3,5,6,6a,7,8,9,9a,decahydrocyclopenta[f][1]benzopyran-7β-ol, as an oil.
Example 8
(±)-4-(3-Oxo-7,7-phenylenedioxyoctyl)-1a,β-methyl-perhydroindan-1,5-dione
10.76 G. of the crude enol ether, (±)-3-(4,4-phenylenedioxypentyl)-6a,β-methyl-1,2,3,5,6,6a,7,8,9,9a-decahydrocyclopenta[f][1]benzopyran-7β-ol dissolved in acetone (210 ml.) was treated with aqueous sulphuric acid solution (50 ml; .5N) and left at room temperature for 2 hr. (followed by tlc). Dilution with ether (500 ml.) and washing with brine (5 × 100 ml.) and saturated aqueous sodium bicarbonate solution (1 × 50 ml.) [all aqueous extracts were backwashed with ether (1 × 100 1 .)]gave the hemiketal, (±)-3-(4,4-phenylenedioxypentyl)-6aβ-methyl-4-hydroxyperhydrocyclopenta[f][1]benzopyran-7β-ol as a glass.
This material was virtually pure by tlc and showed no enol ether band in the ir. The strong hydroxyl bands at 3450 and 3757 cm. and the characteristic catechol-ketal bands were most pronounced. 10.37 G. of this crude hydration product, was dissolved in acetone (200 ml.) cooled in an ice bath and treated at 0°-5° with fresh Jones.sup.(5) chromic acid mixture (20 ml.) over 10 min. After stirring a further 11/2 hr. at room temperature, aqueous sodium bisulphite solution (100 ml; 10%) and brine (100 ml.) were added and the organic materials were isolated with benzene (4 × 200 ml.). The benzene extract was washed with brine and aqueous sodium carbonate solution (10%) to give the neutral triketone, (±)-4-(3-oxo-7,7-phenylenedioxyoctyl)-1a,β-methyl-perhydroindan-1,5-dione as a pale yellow liquid. This material showed one major spot on tlc and had bands in the ir spectrum (film) at 1730 cm.sup. -1 (cyclopentanone, 1705 cm.sup. -1 (saturated carbonyl) and 1480, 1240 and 730 cm.sup. -1 (catechol ketal).
Example 9 (±)-6-(3,3-Phenylenedioxybutyl)-3a,β-methyl-4,5,8,9,9a,9b,-hexahydro-1H-benz[e]indene-3,7(2H,8H)-dione
8.6 G. of a solution of the crude triketone, (±)-4-(3-oxo-7,7-phenylenedioxyoctyl)-1a,β-methyl-perhydroindan-1,5-dione in methanol (250 ml.) containing 1 g. of potassium hyroxide was heated at reflux, under nitrogen, for 1 hr. (followed by ir). Benzene (500 ml.) was added and the mixture was extracted with dilute aqueous sulphuric acid (3 × 50 ml .5N), saturated sodium bicarbonate solution (1 × 100 ml.), brine and then dried over MgSO 4 (note: all aqueous extracts were backwashed with benzene). Removal of the solvents in vacuo furnished the crude tricyclic material, (±)-6-(3,3-phenylenedioxybutyl)-3a,β-methyl-4,5,8,9,9a,9b-hexahydro-1H-benz[e]indene-3,7(2H,8H)-dione as a semi-solid. This material was digested with ethanol (50 ml.) to give the crystalline material, mp 166°-170°.
A sample of this material was recrystallized from ethanol to yield pure colorless crystals, m.p. 173°-175°.
Example 10
(±)-19-Nor-androst-4-ene-3,17-dione
4.01 G. of crude (±)-6-(3,3-phenylenedioxybutyl)-3a,β-methyl-4,5,8,9,9a,9b-hexahydro-1-H-benz[e]indene-3,7(2H,8H)-dione was dissolved in THF (45 ml.) containing triethylamine (.8 ml.) and 400 mg. of a 5 percent Pd/C catalyst and hydrogenated at room temperature and pressure. After 6 hr., the uptake of hydrogen ceased (280 ml. consumed; theory 285 ml/RTP). The solids were filtered off, washed with THF and the filtrate was taken to dryness in vacuo. The crude hydrogenation product (±)-6-(3,3-phenylenedioxybutyl)-3a,β-methyl-4,5,5a,6,8,9,9a,9b-octahydro-1H-benz[e]indene-3,7-(2H,8H)-dione (some solvent residue) showed bands in the ir spectrum (film) at 1705 cm.sup. -1 (cyclohexanone), 1735 cm.sup. -1 (cyclopentanone) and 1480, 1240 and 740 cm.sup. -1 (catechol ketal) and was virtually one spot material on tlc. 4.3 G. of this crude hydrogenation material was dissolved in methanol (70 ml.) and 35 ml. of 4N HCl and the solution was heated at reflux for 6 hr. (followed by tlc and ir). The mixture was cooled, treated with benzene (200 ml.) and extracted with aqueous caustic soda solution (1N; 3 × 100 ml.) and brine (2 × 50 ml.). (All aqueous extracts were backwashed with benzene). Removal of the solvents in vacuo gave crude 19-nor-androst-4-en-3,17-dione which on crystallization from dichloromethane/isopropyl ether mixture yielded pure (±)-19-norandrost-4-ene-3,17-dione, m.p. 155°-157°, identical in all respects with authentic (±)-19-nor-androst-4-ene-3,17-dione, mp. mx mp. tlc, ir, and uv.
Example 11
(±)3-(4,4-Phenylenedioxypentyl)-6a,β-ethyl-1,2,3,5,6,6a-hexahydrocyclopenta[f][1]benzopyran-7(8H)-one
(±) 2-(2-diethylaminoethyl)-6-(4,4-phenylenedioxypentyl) -tetrahydropyran-2-ol (3.8 g.) in toluene (20 ml.) was added to a refluxing solution of 2-ethylcyclopentan-1,3-dione (2 g.) in toluene (40 ml.) and acetic acid (20 ml.) and heated at reflux for 1 hour.
Isolation of the organic material with toluene gave pure (±) 3-(4,4-phenylenedioxypentyl)-6a,β-ethyl-1,2,3,5,6,6a-hexahydrocyclopenta[f][1]benzopyran-7(8H)-one (2.95 g.) after chromatography on alumina. Uv. (EtOH) λmax 252 mμ. (εmax 16 ,000) Calcd. for C 25 H 30 O 4 : C, 76.11; H, 7.67; Found C, 75.68; H, 7.83.
Example 12 (±) 6-(3,3-phenylenedioxybutyl)-3a,β-ethyl-4,5,8,9,9a,9b-hexahydro-1H-benz[e ]inden-3,7(2H,3aH)-dione
Crude (±) 3-(4,4-phenylenedioxypentyl)-6a,β-ethyl-1,2,3,5,6,6a-hexahydrocyclopenta[f][1]benzopyran-7(8H)-one (47 g.) dissolved in tetrahydrofuran (200 ml.) was added to a cold (-10°) slurry of lithium aluminum hydride (6 g.) in tetrahydrofuran (200 ml.).
After stirring for 2 hours at room temperature, saturated aqueous sodium sulfate solution was added (40 ml.) and the solids were filtered off.
Removal of the solvents in vacuo gave racemic 3-(4,4-phenylenedioxypentyl)-6a,β-ethyl-1,2,3,5,6,6a,7,8-octahydrocyclopenta[f][1]benzopyran-7β-ol as an oil (51 g.). Ir. (film) 3400 (OH); 1640 dienol ether); 1450,1240 and 730 cm.sup. -1 catechol ketal.
The above crude material was dissolved in toluene, treated with Pd/C (5%; 5 g.) and hydrogenated at room temperature and pressure until the hydrogen uptake stopped (approximately 30 hours).
The solids were filtered off and the solvents removed in vacuo to yield crude (±) trans-3-(4,4-phenylenedoxypentyl)-6a,βml.) a,7,8,9,9a-decahydrocyclopenta[f][1]-benzopyran-7β-ol as an oil (48 g.). Ir. (CHCl 3 ) 3425 and 3580 (OH) 1480 cm.sup. -1 (catechol ketal).
The above material was dissolved in acetone (500 ml.) treated with dilute aqueous sulfuric acid (0.5 N; 50 ml. ) and left to stand at room temperature for 2 hours. The solution was then cooled to 5° and treated over 30 minutes with fresh Jones chromic acid reagent (125 ml.). The mixture was then stirred for a further 2 hours at room temperature and then quenched with aqueous sodium bisulfite solution (20%; 50 ml.).
Isolation of the organic materials with benzene and extration with aqueous sodium carbonate solution gave racemic trans-4-(3-oxo-7,7-phenylenedioxyoctyl)-1a,β-ethyl-perhydroindane-1,5-dione (34.4 g.) after removal of the organic solvents in vacuo. I.R. (Film) 1735 (cyclopentanone); 1708 (cyclohexanone and straight chain ketone); 1480; 1275 and 740 cm.sup. -1 (catechol ketal).
The crude bicyclic material (34.4 g.) was dissolved in methanol (110 ml.) and added to a reflux solution of potassium hydroxide (3.5 g.) in methanol (200 ml.).
After 1 hour at reflux the organic materials were isolated with benzene and chromatography on silica gel (800 g.) gave racemic 6-(3,3-phenylenedioxybutyl)-3a,β-ethyl-4,5,8,9,9a,9b-hexahydro-1H-benz[e]inden-3,7-(2H,3aH)-dione (20 g.) as an oil. I.R. (CHCl 3 ) 1735 (cyclopentanone); 1663 AND 1600 (cyclohexanone); 1480 cm.sup. -1 (catechol ketal).
Example 13
(±)-13β-ethylgon-4-en-3,17-dione
Racemic 6-(3,3-phenylenedioxybutyl)-3a,β-ethyl-4,5,8,9,9a,9b-hexahydro-1H-benz[e]inden-3,7-(2H,3aH)-dione (20 g.) was dissolved in ethanol (250 ml.) containing triethylamine (2 ml.) and Pd/C (5%; 4g.) and hydrogenated at room temperature and pressure until the uptake of hydrogen stopped to yield 6-(3,3-phenylenedioxy)3a,β-ethyl-4,5,5a,6,8,9,9a,9b-octahydro-1H-benz[e]indene-3,7-(2H,8H)-dione in solution.
The solids were filtered off and dilute aqueous hydrochloric acid (4N; 200 ml.) was added and the mixture was heated at reflux for 5 hours.
The organic materials were isolated with benzene and the benzene extract was then washed free of catechol with dilute aqueous caustic soda solution.
Removal of the solvents in vacuo yielded a semisolid which on crystallization from dichloromethane-isopropyl ether mixture yielded pure racemic 13β-ethylgon-4-en-3,17-dione (6.3 g.) m.p. 159°-161°.
Example 14
2R,6S-2[2-(R-α-phenethylamino)ethyl]-6-(4,4-phenylenedioxy-pentyl) tetrahydropyran-2-ol and 2S,6R-2[2-(R-α-phenethylamino)-ethyl]-6-(4,4-phenylenedioxypentyl) tetrahydropyran-2-ol
(±) 9,9-Pheneylenedioxy-5-hydroxy decanoic acid lactone (11.1 g.) dissolved in tetrahydrofuran (100 ml.) at -50° was treated with vinylmagnesium chloride solution (39 ml.; 2 molar in T.H.F.) over 3 minutes. The mixture was then stirred at -45° for 25 minutes, quenched with methanol (10 ml.) and ammonium chloride solution (15%; 100 ml.) and extracted with ether.
Removal of the solvents in vacuo gave the crude vinyl ketone as an oil. This material was dissolved in benzene (20 ml.) and treated with a solutino of α-phenethylamine (3.9 g.) in benzene (20 ml.) and left at room temperature for 3 hours.
The solvents were removed in vacuo and the residue extracted with hexane. This hexane extract was filtered through alumina (50 g.) to give the mixture of diastereomeric bases (11 g.) as a liquid.
This material was dissolved in hexane and left to crystallize. Recrystallization yielded the pure 2S,6R,2-[2-(R-α-phenethylamino)ethyl]6-(4,4-phenylenedioxypentyl)-tetrahydropyran-2-ol, m.p. 72°-76°; [α D] =+37° (c = 5 , benzene).
The mother liquors from the first crystallization were taken to dryness and dissolved in acetone (25 ml.). This solution was added to oxalic acid (2 g.) in acetone (30 ml.) and left to crystallize.
Recrystallization of the solids from acetone yielded pure 2R,6S,2-[2-(R-α-phenethylamino)ethyl]-6-(4,4-phenylenedioxypentyl) tetrahydropyran-2-ol oxalate, m. p. 80°; [α D] = +21° (c = 1.248, methanol).
Example 15
3S,6aS,3-(4,4- phenylenedioxypentyl)-6a,β-methyl-1,2,3,5,6,6a-hexahydrocyclopenta[f][1]benzopyran-7(8H)-one
2S,6R-2[2-(R-α-phenethylamino)ethyl ]-6-(4,4-phenylenedioxypentyl) henylenedioxypentyl) tetrahydropyran-2-ol (1.25 g.) in toluene (45 ml.) and aqueous acetic acid (18 ml.; 95%) was treated with pyridine (9ml.) and 2-methylcyclopentane-1,3-dione (0.5 g.) and heated at 110° for 7 hours. After this time the water was taken off with a Dean-Stark separator (˜45 minutes) and the mixture cooled.
Isolation of the materials with benzene and chromatography on alumina yielded the dienol ether.
Crystallization from hexane gave optically pure 3S,6a,S,3-(4,4-phenylenedioxypentyl)6a,β-methyl-1,2,3,5,6,6a-hexahydrocyclopenta[f][1]benzopyran-7(8H)-one, m.p. 109°-112°, [α D] =-121° (c = 1.0 , CHCl 3 ).
Example 16
(±)-19-norandrost-4-en-3,17-dione
3R,6aS,3-(4,4-phenylenedioxypentyl)-6a,β-methyl-1,2,3,5,6,6a-hexahydrocyclopenta[f][1]benzopyran-7(8H)-one was converted in good yield into the above-captioned product having a melting point of 172° using the procedure of Examples 6, 7, 8, 9 and 10.
Example 17
(±)-6-(4,4-Phenylenedioxypentyl)-tetrahydropyran-2-ol
Freshly distilled glutaraldehyde (100 g.) dissolved in dry THF (700 ml.) was cooled to -65°treated and treated rapidly with the cold general, 20°) Grignard reagent over ˜30 min. (the temperature maintain held at range of 60°→ -50°C. with a dry ice acetone bath). The mixture was then allowed to warm up to room temperature (˜1 hr.) and then stirred a further 90 min. at room temperature (Note: sometimes on warming to room temperature an exotherm sets in and cooling is required). The reaction mixture can be stored 16-24 hr. at 5° or worked up after 90 min. at room temperature.
To work up, the reaction mixture was cooled to 5° and treated with an aqueous solution of ammonium chloride (150 ml.; 25 percent). The solids were filtered off, washed well with more THF and the THF was removed in vacuo to yield the crude hemiacetal (±) -6-(4,4-phenylenedioxypentyl)-tetrahydropyran-2-ol (270 g.). This material assayed for ˜75 percent purity by chromatography on siliAca gel. The starting material may be prepared as follows:
A. Preparation of the Grignard reagent
A total of 100 ml. of a solution of 2,2-phenylenedioxy5-chloropentane in dry tetrahydrofuran obtained by adding 213 g. of the chloroketal to 1.4 1. of THF distilled from calcium hydride was added to 28 g. of magnesium turnings activated with iodine under nitrogen.
The mixture was then heated to 36°-38° for ˜5 min. and then treatd with dibromoethane (0.5 ml.). In genera, the reaction became mildly exothermic at this point and had to be cooled to maintan the temperature rangeof 36°-38°C. After stirring 15-20 min. more, the rest of the chloroketal solution was added over ˜1 ;l hr. Again cooling was required. After stirring a further 45-60 min. the exotherm subsided and the mixture was heated to 36°-38° for a further 2 hours after which time virtually no starting material remains.
The Grignard reagent can be stored under nitrogen at 5° for several days. The progress of the reaction was followed by vapor phase chromatography. Thus, an aliquot (0.5 ml.) of the reaction mixture was added to aqueous ammonium chloride solution (2 ml; 15 percent) and ether (0.5 ml.). The organic extract was then analyzed at 150°C. on an 8 × 1/4 inch column with 3 percent SE 30 silicone on chom. w. (80-100) AW-DAKS.
B. Production of dry glutaraldehyde
Aqueous glutaraldehyde solution (1 1.; 50 percent Union Carbide) was treated with benzene (2 1.) cooled to 5° and dried with magnesium sulfate (700 g.) for 15 min. The solution was then heated at reflux for 1 hr. in conjunction with a Dean and Stark water separator. The solvents were then removed in vacuo (50°at 10 mm) and the residue distilled to give a center cut (315 g.) of dry glutaraldehyde, b.p. 80°-81°/˜10 mm.
Example 18
(±)-9,9-Phenylenedioxy-5-hydroxy-decanoic acid lactone
a. A solution of sodium hydroxide (91 g.) in water (225 ml.) was added to silver nitrate (195 g.) dissolved in water (650 ml.) at room temperature and then the mixture was heated to 55°-60°. Methanol (1300 ml.) was then added and the temperture fell to 45°. A solution of (±)-6-(4,4-phenylenedioxypentyl)-tetrahydropyran-2-ol (107.7 g. crude) in methanol (150 ml.) was then added over 10 min. The temperture rose to 53° and after the initial exotherm the mixture was heated, with stirring, under nitrogen for a further 1 hr. The solids were filtered off and washed well with a methanol-water mixture (1:1; 3 × 200 ml.). The filtrate was then extracted with toluene (500 ml.) acidified to pH 1 with aqueous sulfuric acid (6N) and extracted with dichloromethane (4 × 500 ml.). Removal of the solvents in vacuo yielded a mixture of the lactone and hydroxy acid (83 g.). This material was dissolved in benzene (500 ml.) and treated with p-toluenesulfonic acid (2 g.) in more benzene (100 ml.). After standing for 1 hr. at room temperature the mixture was washed with aqueous sodium bicarbonate solution and the organic solvents were removed in vacuo to yield virtually pure lactone (±)-9,9-phenylenedioxy-5-hydroxy-decanoic acid lactone (76 g.) (as estimated by tlc and ir).
b. The hemiacetal (±)-6-(4,4-phenylenedioxypentyl)-tetrahydropyran-2-ol (1.77 g.) in ethyl acetate (100 ml.) containing platinum black (922 mg.) was stirred at room temperature under an atmosphere of oxygen for 48 hr. The solids were filtered off and the product (±)-9,9-phenylenedioxy-5-hydroxy-decanoic acid lactone was isolated by distillation (1.5 g.).
c. The crude hemiacetal (±)-6-(4,4-phenylenedioxypentyl)tetrahydropyran-2-ol (233 g.) dissolved in toluene (1.2 l.) was added to a solution of sodium dichromate bishydrate (315 g.) in acetic acid (1.2 l.). The reaction mixture was held at 35° with cooling until no longer exothermic (˜2 hrs.), and then stirred ˜16 hrs. at room temperature. Water (2.5 l.) was added and the materials were isolated with toluene (4 × 500 ml.). The combined toluene extracts were washed with brine and distilled to give the lactone (±)-9,9-phenylenedioxy-5-hydroxy-decanoic acid lactone (125 g.) of moderate purity (˜80 percent). A purer product was obtained when the toluene layer was washed first with aqueous sodium bicarbonate solution (44-46 percent yield vpc pure).
d. The crude hemiacetal (±)-6-(4,4-phenylenedioxypentyl)-tetrahydropyran-2-ol (78 g.) in DMF (400 ml.) was added to a solution of bromine (30.5 ml.) in a buffer mixture (640 ml.) (420 ml. H 2 O/480 DMF/160 ml. AcOH/160 g. NaOAc.2H 2 O) at 0°-5°C.
After stirring 1 hr. at room temperature, aqueous sodium bisulfite was added (250 ml; 15 percent) and the organic materials were isolated with benzene. Removal of the solvents gave a brown colored oil which was dissolved in methanol (500 ml.) and treated with potassium hydroxide (30 g.) dissolved in water (300 ml.). After 30 min. at room temperature, water (500 ml.) was added and the mixture was extracted with ether. The aqueous phase was acidifed and extracted with methylene chloride. Removal of the solvents "in vacuo" and distillation of the residue (oil jacketed flask at 0.3 mm) gave the lactone (±)-9,9-phenylenedioxy-5-hydroxy-decanoic acid lactone (29-33 g.). This material was contaminated by some aromatic-ring brominated material.
Example 19
2S,6R-2-[2-(S-α-phenethylamino)ethyl]-6-(4,4-phenylenedioxypentyl)-tetrahydropyran-2-ol oxalate
The lactone (±)-9,9-phenylenedioxy-5-hydroxy-decanoic acid lactone (188 g.) dissolved in THF (1 l.) was cooled to -70°C. under nitrogen. A solution of vinyl magnesium chloride (315 ml; 2.28 molar) in THF was added over 6 min. (temp. held between -50° and -70°) and the mixture was then stirred a further 14 min. at -50. After this time the temperature was lowered to -65° and methanol (50 ml.) was added (3 min.) followed by aqueous ammonium chloride solution (500 ml; 10 percent). (The temperature rose to ˜-5°).
The products were then isolated with ether (5 × 500 ml.) and dried with MgSO 4 . The solids were filtered off and the filtrate was concentrated to ˜200 ml. in vacuo at 40°-45°. The concentrate was treated with benzene (250 ml.) and a solution of (S)-α-phenethylamine (51 g.) in benzene (150 ml.) and kept at room temperature overnight (3-4 hr. will suffice; slight cooling is initially required). The solvents were taken to dryness and the residue (193 g.) was extracted with boiling hexane (1 × 500 ml. and 2 × 250 ml.) and the combined hexane extracts were again taken to dryness in vacuo. The residue (157.2 g.) was dissolved in acetone (400 ml.) and added to a solution of oxalic acid (49 g.) in acetone (400 ml.) After standing 8 hr. at room temperature and 8 hr. at ˜5°, the solids were filtered off, washed with acetone (2 × 100 ml.) and dried over P 2 O 5 at 0.5 mm. This solid (84.2 g.) had m.p. 78°-82°, [α] D -21° (c = 6.45, methanol) and was recrystallized from methyl ethyl ketone (1.1 l.) (some insoluble solids were filtered off) and gave pure 2S, 6R-2-[2-(S-α-phenethylamino)ethyl]-6-(4,4-phenylenedioxypentyl)-tetrahydropyran-2-ol oxalate (51.2 g.), m.p. 81°-83°, α D -23.3° (c = 3.95, methanol).
Anal. Calcd for C 26 H 35 NO 4 (CO 2 H) 2 : C, 65.23; H, 7.23; N, 2.72. Found: C, 64.91; H, 7.09; H, 2.49.
All the mother liquors were taken to dryness and the residue was partitioned between water (800 ml.) and hexane (400 ml.). The aqueous phase was re-extracted with hexane (400 ml.) and the combined hexane extracts were then washed with aqueous acetic acid (10 percent).
All the aqueous phases were combined and made basic with sodium carbonate solution (130 g. in 400 ml. H 2 O). The organic materials were extracted into hexane and yielded an oily solid on concentration (75 g.). This material was recrystallized three times from hexane to give pure 2R,6S-2-[2-(S-α-phenethylamino)-ethyl]-6-(4,4-phenylenedioxypentyl)-tetrahydropyran-2-ol (40 g.), m.p. 78°-80°; [α] D -37° (c = 3.42; benzene).
Anal. Calcd. for C 26 H 35 NO 4 : C, 73.38; H, 8.29; N, 3.29. Found: C, 73.68; H, 8.40; N, 3.47.
All the above mother liquors were taken to dryness and dissolved in a mixture of acetone (100 ml.) and dilute aqueous sulfuric acid (1N; 100 ml.) and left to stand at room temperature for 2 hr. The mixture was made basic with aqueous sodium carbonate solution and the products were isolated with hexane. (This hydration procedure was necessary as extensive dehydro Mannich base was generated in all the manipulations; particularly in the oxalate recrystallization).
The crude extract (˜19 g.) in acetone (50 ml.) was added to oxalic acid (6 g.) in more acetone (50 ml.). Recrystallization of the precipitate (15.8 g., m.p. 75°-78°) from methyl ethyl ketone gave a further quantity of pure oxalate salt (12.9 g.) [α] D -23.6° (c = 3.19, methanol).
[Note: Both the melting points and the rotations of the oxalate salts are dependent on the severity of the drying. This is probably due to the possible formation of solvates.]
Example 20
2S,6R-2-[2-(R-α-phenethylamino)ethyl]-6-(4,4-phenylenedioxypentyl)-tetrahydropyran-2-ol
The procedure of Example 19 methanol-water-hexane-acetic repeated with the enantiomeric amine (R)-α-phenethylamine. Thus, the lactone (±)-9,9 -phenylenedioxy-5-hydroxy-decanoic acid lactone (54 g, 80-90 percent purity) generated a crude base (˜90 g.) which was processed as follows.
The crude product was partitioned between methanol-waterhexane-acetic acid (300:300:50:350 ml.). The hexane extract was washed with methanol-water-acetic acid (100 ml; 1:1:0.2). The combined "aqueous" phases were then extracted with hexane/benzene mixture (400 ml; 2:1) and then made basic with cold aqueous caustic potash (4N; ˜250 ml.) (gave bad emulsion). Extraction with hexane then gave the purified amine base (58 g.) as an amber colored oil. Crystallization from hexane gave pure 2S, 6R-2-[2-(R-α-phenethylamino)ethyl]-6-(4,4-phenylenedioxypentyl)tetrahydropyran-2-ol (17.7 g; after combining other crops), m.p. 75°-77°, [α] D +37° (c = 1.053; benzene).
Anal. Calcd. for C 26 H 35 NO 4 : C, 73.38; H, 8.29; N, 3.29. Found: C, 73.63; H, 8.41; N, 3.26.
All the hexane mother liquors were taken to dryness (37 g.), dissolved in acetone (100 ml.) and added to oxalic acid (14 g.) dissolved in acetone (100 ml.). The solid formed (31 g.) was recrystallized from methyl ethyl ketone (250 ml.) to give 2R,6S-2-[2-(R-α-phenethylamino)-ethyl]-6-(4,4-phenylenedioxypentyl)-tetrahydropyran-2-ol oxalate (26.6 g.), m.p. 81°-83° [α] D +22.7° (c = ˜4; methanol).
Anal. Calcd. for C 26 H 35 NO 4 (CO 2 H) 2 : C, 65.23; H, 7.23; N, 2.72. Found: C, 65.31; H, 7.31; N, 2.7.
Example 21
3S,6aS-3-(4,4-phenylenedioxypentyl)-6a,β-methyl-1,2,3,5,6,6a-hexahydrocyclopenta[f][1]benzopyran-7,(8H)-one
a) From 2S,6R-2-[2-(R-α-phenethylamino)ethyl]-6-(4,4-phenylenedioxypentyl)tetrahydropyran-2-ol
The crystalline free base 2S,6R-2-[2-(R-α-phenethylaminoethyl]-6-(4,4-phenylenedioxypentyl)-tetrahydropyran-2-ol (15.02 g.) was dissolved in a mixture of methanol (300 ml.) benzaldehyde (5.42 g.) and sodium bicarbonate (1.07 g.) and heated at reflux, under nitrogen, for 11 hr. The solvents were removed in vacuo and the residue was partitioned between ether and dilute aqueous hydrochloric acid (2N). The ether layer was then washed with aqueous sodium bisulfite solution (3 × 100 ml; 20 percent), brine and dried over sodium sulfate. Removal of the solvents in vacuo yielded the methanol adduct 2S-(2-methoxyethyl)-6R-(4,4-phenylenedioxypentyl)tetrahydropyran-2-ol (12.6 g.) as an oil [α] D +8.94 (c = 1.6328, benzene) having ir bands (film) at 3475 (OH): 1712 (open ketohydroxy form); 1490, 1240 and 740 cm - 1 (catechol ketal). This compound presumably comprises the open and closed form tautomers. The crude methanol adduct (12.6 g.) was dissolved in a mixture of toluene (300 ml.), acetic acid (150 ml.), water (5 ml.) containing 2-methylcyclopentan-1,3-dione (4.47 g.) and heated at reflux for 8 hr. A Dean and Stark water trap was then attached and the mixture was heated at reflux for a further 90 min. The mixture was cooled, treated with benzene (500 ml.) and washed with water, aqueous sodium carbonate solution and dried over MgSO 4 . Removal of the solvents in vacuo gave an orange colored gum (15.3 g.). Crystallization from isopropyl alcohol (140 ml.) gave the dienol ether 3S,6aS-3-(4,4-phenylenedioxypentyl)-6a,β-methyl-1,2,3,5,6,6a-hexahydrocyclopenta[f][1]benzopyran-7,(8H)-one (7.9 g.). Recrystallization gave pale orange needles (7.3 g.), m.p. 112°-113°, [α] D -122.3° (c = 1.15; chloroform).
Anal Calcd. for C 24 H 28 O 4 : C, 75.76; H, 7.42. Found C, 75.99; H, 7.63.
b. From 2S, 6R-2-[2-(S-α-phenethylamino)ethyl]-6-(4,4-phenylenedioxypentyl)-tetrahydropyran-2-ol oxalate
The oxalate salt (α D -23.3°; 15.45 g.) was dissolved in methanol (360 ml.) containing sodium bicarbonate (6 g; anhydrous) and benzaldehyde (4.5 ml.) and heated under nitrogen at reflux for 16 hr. The methanol adduct was then worked up as in (a) above to yield the methanol adduct as a pale yellow colored oil (9.9 g.); ir (film) 3450(OH), 1700 (sat >C=O open hemiketal), 1480, 1260, 770 (catechol ketal), 1100 cm - 1 (methoxy). Conversion of this product to the dienol ether followed the procedure of (a) above and gave pure 3S,6aS,3-(4,4 -phenylenedioxypentyl)-6a,β-methyl-1,2,3,5,6,6a-hexahydrocyclopenta[f][1]benzopyran-7,(8H)-one (5.5 g.) [α] D -121° (c = ˜2; chloroform).
c. Direct conversion of 2S,6R-2-[2-(R-α-phenethylamino) ethyl]-6-(4,4-phenylenedioxypentyl)tetrahydropyran-2-ol
A total of 850 mg. of 2S,6R-2-[2-(R-α-phenethylamino) ethyl]-6-(4,4-phenylenedioxypentyl)tetrahydropyran-2-ol was dissolved in a mixture of toluene (30 ml.), aqueous acetic acid (12 ml; 90 percent) pyridine (6 ml.), 2-methylcyclopentan-1,3-dione (330 mg.) and heated at reflux under nitrogen for 16 hr. A Dean and Stark water trap was then attached and the water was separated for 35 min. Work up as in (a) above and filtration of the crude product through alumina (5 0 ml; grade III neutral) gave the dienol ether mixture (575 mg.) as a pale yellow solid. Crystallization from isopropyl alcohol gave 3S,6aS-3-(4,4-phenylenedioxypentyl)-6a,β-methyl-1,2,3,5,6,6a-hexahydrocyclopenta[f][1]benzopyran-7,(8)-one as needles (397 mg.) [α] D -119° (c = ˜2; chloroform); recrystallization raised the rotation to [α] D -121° .
Example 22
C/D-trans-3-(4,4-phenylenedioxypentyl)-6a,β-methyl-1,2,3,5,6,6a,7,8,9,9a-decahydrocyclopenta[f][1]benzopyran-7β-ol
The dienol ether 3S,6aS-3-(4,4-phenylenedioxypentyl)-6a,β-methyl-1,2,3,5,6,6a-hexahydrocyclopenta[f][1]benzopyran-7,(8H)-one (14 g.) dissolved in THF (100 ml.) was added to a slurry of lithium aluminum hydride (5 g.) in THF (100 ml.) at 5°C. After stirring for 2 hr. at room temperature wet ether (200 ml.) and saturated aqueous sodium sulfate solution (30 ml.) was added. After stirring a further 1 hr. at room temperature the solids were filtered off and washed with ether. After drying the combined filtrate over MgSO 4 the solvents were taken to dryness in vacuo to yield a glass (15.5 g.). This material was dissolved in dry THF (100 ml.), treated with 5 percent Pd/C (1.5 g.) and hydrogenated at room temperature and pressure. After one mole of hydrogen had been consumed (usually 2-8 hr. required), the solids were filtered off, washed with more THF and the combined filtrates taken to dryness in vacuo. This gave a mixture of the above-titled enol ethers (15 g.). The nmr spectrum showed two methyl signals for the C 6a methyl indicating ˜3:1 mixture of the C/D trans to the C/D cis isomers.
Example 23
(+)-6-(3,3-phenylenedioxybutyl)-3a,β-methyl-4,5,8,9,9a,9b-hexahydro-1H-benz[e]indene-3,7-(2H,3aH)-dione
The crude enol-ether mixture C/D trans-3-(4,4-phenylenedioxypentyl)-6a,β-methyl-1,2,3,5,6,6a,7,8,9,9a-decahydrocyclopenta[f] [1]benzopyran-7β-ol (15 g.) dissolved in acetone (150 ml.) was treated with aqueous sulfuric acid (.5N; 50 ml.) at room temperature for 2 hr. (followed by tlc). Brine (500 ml.) was added and the products were isolated with ether to give a glass which contained a major amount of 3-(4,4-phenylenedioxypentyl)-4-hydroxy-6aβ-methyl-perhydrocyclopenta[f][1]benzopyran-7β-ol. This material dissolved in acetone (300 ml.) was cooled to 0°-5° and treated over 20 min. with fresh Jones chromic acid mixture (45 ml.). The mixture was then stirred an additional 21/2 hr. at room temperature. Aqueous sodium bisulfite solution (100 ml; 10 percent) and brine (250 ml.) were added and the products were isolated by extraction with benzene. The combined benzene extracts were washed with dilute sodium carbonate solution (5 percent; 100 ml.) and taken to dryness in vacuo. The crude triketone 4-(3-oxo-7,7-phenylenedioxyoctyl)-1aβ-methyl-perhydroindan-1,5-dione (13.3g.) showed strong bands in the infra red spectrum (chloroform) at 1735 and 1710 and 1480 (catechol ketal) cm - 1 and no hydroxyl band. The crude triketone was dissolved in methanol (100 ml.) and added to a solution of potassium hydroxide (2 g.) in methanol (50 ml.) under nitrogen. The deep red colored solution was then heated at reflux for 90 min., treated with acetic acid (3 ml.) and taken to dryness. The residue was partitioned between benzene and sodium carbonate solution (5 percent) and gave the crude tricyclic material (+)-6-(3,3-phenylenedioxybutyl)-3a,β-methyl-4,5,8,9,9a,9b-hexahydro-1H-benz[e]indene-3,7-(2H,3aH)-dione on concentration to dryness (11.1 g.). Crystallization from methylene chloride: isopropyl ether mixture (10:30) gave crystalline material (6.43 g.). This material was dissolved in ethanol (50 ml.) and left at room temperature, twice filtered free of solids (˜20 min. intervals) and then cooled to 5° and seeded with pure product. After 16 hr. (at 0°-5°) the solids were isolated (4.5 g.), m.p. 118°-120°, [α] D +40.34° (c = ˜2; chloroform). From the various mother liquors a further quantity of material (1.06 g.) was obtained, m.p. 116°-119° [α] D +40.39° (c = ˜2; chloroform).
A sample of the bulked material was filtered through alumina (neutral, grade III) in benzene and recrystallized from ethanol to yield the analytical sample of (+)-6-(3,3-phenylenedioxybutyl)-3a,β-methyl-4,5,8,9,9a,9b-hexahydro-1H-benz[e]indene-3,7-(2H, 3aH)-dione, m.p. 117°-119°, [α] D +40.77 (c = 1.7267, chloroform).
Anal. Calcd. for C 24 H 28 O 4 : C, 75.76; H, 7.42. Found: C, 75.96; H, 7.31.
Example 24
(+)-19-Nor-androst-4-ene-3,17-dione
The tricyclic compound (+)-6-(3,3-phenylenedioxybutyl)-3a,β -methyl-4,5,8,9,9a,9b-hexahydro-1H-benz[e]indene-3,7-(2H,3aH)-dione (3.8 g; [α] D +40.34°) was dissolved in THF (35 ml.) containing triethylamine (0.7 ml.) and 5 percent Pd/C (0.4 g.) and hydrogenated at room temperature and pressure until one mole equivalent of hydrogen had been consumed. The solids were filtered off and the filtrate was taken to dryness in vacuo to yield a colorless glass. This material was dissolved in ethanol (30 ml.), treated with aqueous hydrochloric acid (2N; 20 ml.) and heated at reflux under nitrogen for 4 hr. The solvents were partially removed in vacuo and the residue was extracted with benzene. The combined benzene extracts were washed with aqueous sodium carbonate solution (10 percent) and sodium hydroxide solution (1N). Removal of the solvents gave a white solid (2.8 g.), [α] D +125° (c = 2.2°, chloroform). Recrystallization from methylene chloride-isopropyl ether mixture gave crystalline material (2.08 g.), m.p. 169°-172° (hot stage); 168°-170° (Hoover) [α] D +139.5° (c = 3.03; chloroform). Recrystallization from aqueous methanol gave pure (+)-19-nor-androst-4-ene-3,17-dione (1.86 g.), m.p. 172°-174° (hot stage) and 168°-170° (Hoover) [α] D +141.9° .
Example 25
4,4-(2,3-Naphthalenedioxy)-1-chloropentane
A mixture of 2,3-naphthalenediol (13.3 g.) and 5-chloro-2-pentanone (5 g.) in benzene (100 ml.) containing p-toluenesulfonic acid (100 mg.) was heated at reflux under nitrogen in conjunction with a Dean and Stark water trap for 18 hr. The cold reaction mixture was treated with benzene (100 ml.) and washed with aqueous sodium carbonate solution (3 × 30 ml; 10 percent), brine and dried over magnesium sulfate (MgSO 4 . anhydrous). The solids were filtered off and the filtrate was passed through a column of alumina (25 ml; neutral grade III). Removal of the solvents in vacuo gave an oil (7.3 g.) which yielded pure 4,4-(2,3-naphthalenedioxy)-1-chloropentane (5.4 g.) on distillation, b.p. 139°-141°/0.07 mm.
Anal. calcd. for C 15 H 15 O 2 Cl: C, 68.57; H, 5.75; Cl, 13.49. Found: C, 68.41; H, 5.67; Cl, 13.49.
Example 26
4,4-(4,5-Dimethylphenylene-dioxy)-1-chlorpentane
A mixture of 4,5-dimethylcatechol (34.4 g.) and 5-chloro-2-pentanone (30 g.) in benzene (600 ml.) containing p-toluenesulfonic acid (600 mg) was heated, under nitrogen, at reflux in conjunction with a Dean and Stark water trap for 18 hr. More benzene (300 ml.) was added and the dark colored mixture was washed with aqueous sodium carbonate solution (3 × 150 ml; 10 percent), brine (250 ml.) and dried over MgSO 4 . Removal of the benzene in vacuo gave a dark colored oil which was dissolved in hexane and filtered through alumina (175 ml; neutral grade III).
Removal of the solvent and distillation of the pale yellow colored oil (47.4 g.) yielded pure 4,4-(4,5-dimethylphenylenedioxy)-1-chloropentane after distillation (39.8 g.), b.p. 110°-120°/0.1 mm.
Anal. Calcd. for C 13 H 17 O 2 Cl: C, 64.86; H, 7.12; Cl, 14.73. Found: C, 64.66; H, 7.3; Cl, 14.74.
Example 27
(±)-6-[4,4-(2,3-Naphthalenedioxy)pentyl]-tetrahydropyran-2-ol
Magnesium metal (3 g; powder) was activated with iodine under nitrogen and treated with a solution (70 ml.) of the 4,4-(2,3-naphthalenedioxy)-1-chloropentane in tetrahydrofuran (THF) (20 g. in 200 ml. THF; distilled from calcium hydride). The mixture was heated to 40° and treated with dibromoethane (˜3 ml.). After the initial exotherm (slight) had subsided the rest of the solution was added. The mixture was then heated at 35°-37° for a further 31/2- 4 hr. with stirring. (The progress of the reaction was followed by quenching an aliquote (0.5 ml.) with aqueous ammonium chloride solution (2 ml; 15 percent) and ether (0.5 ml.) and analyzing the organic phase by vpc at 200°C.) Dry redistilled glutaraldehyde (7.6 g.) dissolved in THF (60 ml.) was cooled at -60° and treated with the above Grignard reagent (10-15 min.) keeping the temperature at -60° → -50°. The mixture was then warmed to room temperature over ˜3 hr. After this time (tlc indicated complete reaction) the mixture was cooled to 5° and treated with aqueous ammonium chloride solution (45 ml; saturated). The solids were filtered off, washed well with more THF and the combined filtrate was taken to dryness in vacuo. The crude hemiacetal (±)-6-[4,4-(2,3-naphthalenedioxy)pentyl]-tetrahydropyran-2-ol (24.7 g.) was chromatographed on silica gel (750 g; 0.2-0.5 mm mesh) and yielded pure product (15.6 g.) on elution with benzene-ethyl acetate mixtures (9:1, 4:1 and 7:3).
Anal. Calcd. for C 20 H 24 O 4 : C, 73.14; H, 7.37. Found: C, 72.84; H, 7.67.
Ir showed bands at 3600 (--OH), 1470 and 1250 cm - 1 (napthtalenedioxy).
Example 28
(±)-6-[4,4-(4,5-dimethylphenylenedioxy)pentyl]-tetrahydropyran-2-ol
the chloroketal 4,4-(4,5-dimethylphenylenedioxy)-1-chlorpentane (24 g.) in THF (400 ml.) was converted into the Grignard reagent with magnesium (3.65 g.) as in Example 27. The above solution was then added to dry redistilled glutaraldehyde (10 g.) in THF (150 ml.) as before to yield the crude hemiacetal (±)-6-[4,4-(4,5-dimethylphenylenedioxy)pentyl]-tetrahydropyran-2-ol (32.5 g.) after the same workup. Chromatography on silica gel (900 g; 0.2-0.5 mm mesh) yielded pure material (13.8 g.).
Anal. Calcd. for C 18 H 26 O 4 : C, 70.56; H, 8.55 Found: C, 69.73; H, 8.27.
Ir showed bands at 3600 (--OH), 1500 and 1260 cm - 1 (Phenylenedioxy).
Example 29
(±)-11,11-(2,3-naphthalenedioxy)-3,7-dihydroxy-1-dodecene
The hemiacetal (±)-6-[4,4-(2,3-naphthalenedioxy)penthyl]-tetrahydropyrin-2-ol (15 g.) dissolved in THF (60 ml.) was cooled to 5° and treated with a solution of vinyl magnesium chloride (62.4 ml; 2.2 molar in THF) and stirred at room temperature overnight (2-3 hr. are sufficient). Aqueous ammonium chloride solution (30 ml; 15 percent) was added and the solids were filtered off and washed with more THF. The combined THF filtrates were taken to dryness in vacuo to yield the crude vinyl diol (±)-11,11-(2,3-naphthalenedioxy)-3,7-dihydroxy-1-dodecene (17.2 g.). Chromatography on silica gel (510 g; 0.2-0.5 mm mesh) gave pure product (13.3 g.) on elution with benzene-ethyl acetate mixture (7:3; 1:1 and 1:3).
Anal. Calcd. for C 22 H 28 O 4 : C, 74.13; H, 7.92. Found: C, 73.75; H, 7.80.
Example 30
(±)-11,11-(4,5-dimethylphenylenedioxy)-3,7-dihydroxy-1-dodecene
The hemiacetal (±)-6-[4,4-(4,5-dimethylphenylenedioxy)pentyl]-tetrahydropyran-2-ol (13.7 g.) dissolved in THF (70 ml.) was treated with vinyl magnesium chloride solution (60.5 ml; 2.0 molar in THF) as in Example 29. Workup and chromatography on silica gel as in the previous example gave the pure vinyl diol (±)-11,11-(4,5-dimethylphenylenedioxy)-3,7-dihydroxy-1-dodecene (11.2 g).
Anal. Calcd. for C 20 H 30 O 4 : C, 71.83; H, 9.04. Found: C, 71.79; H, 9.27.
IR shows bands at 3610 and 3450 (--OH), 1500 and 1255 (phenylenedioxy) and 860 cm.sup. -1 (C=CH 2 ).
Example 31
(±)-2-(2-diethylaminoethyl)-4,4-(2,3-naphthalenedioxy)pentyltetrahydropyran-2-ol
Manganese dioxide (140 g.) was added to benzene (400 ml.) and cooled to ˜5°. Diethylamine (400 ml.) was slowly added followed by a solution of the vinyl diol (±)-11,11-(2,3-naphthalenedioxy)-3,7-dihydroxy-1-dodecene (14.4 g.) in benzene (100 ml.). The mixture was stirred at room temperature for 18 hr., filtered free of solids and the residue was washed well with benzene. Removal of the benzene from the combined extracts gave a brown colored oil (21.2 g.). This material was dissolved in ether (200 ml.) and extracted with cold aqueous hydrochloric acid (1N; 4 × 50 ml.). The aqueous phase was made basic with caustic potash solution (2N) and the product was isolated with ether. Removal of the solvents yielded (± )-2-(2-diethylaminoethyl)-4,4-(2,3-naphthalenedioxy)pentyl-tetrahydropyran-2-ol (16.2 g.) as an amber colored oil.
Ir had bands at 3600 (bonded --OH and --NH) 1250 and 1470 cm.sup. -1 (naphthalenedioxy).
Example 32
(±)-2-(2-diethylaminoethyl)-6-[4,4-dimethylphenylenedioxy)pentyl[-tetrahydropyran-2-ol
A solution of the vinyl diol (±)-11,11-(4,5-dimethylphenylenedioxy)-3,7-dihydroxy-1-dodecene (11.5 g.) in benzene (100 ml.) was treated with manganese dioxide (115 g.) as in Example 31. After acid purification the product (±)-2-(2-diethylaminoethyl)-6-[4,4-dimethylphenylenedioxy)pentyl]-tetrahydropyran-2-ol (11.6 g.) was obtained as a pale yellow oil.
Anal. Calcd. for C 24 H 39 NO 4 : C, 71.07; H, 9.69; N, 3.45. Found: C, 70.87; H, 9.74; N, 3.15.
IR showed bands at 3100 (broad, bonded --OH and --NH) 1500 and 1260 cm.sup. -1 (phenylenedioxy).
Example 33
(±)-3-[4,4-(2,3-Naphthalenedioxy)pentyl]-6aβ-methyl-1,2,3,5,6,6a-hexahydro-cyclopenta-[f][1]-benzopyran-7(8H)-one
A mixture of (±)-2-(2-diethylaminoethyl)-4,4-(2,3-naphthalenedioxy)pentyl-tetrahydropyran-2-ol (1.51 g.), toluene (8 ml.), acetic acid (2 ml.) and 2-methylcyclopentan-1,3-dione (470 mg.) was heated at reflux, under nitrogen for 90 min. Dilution with benzene (50 ml.) and extraction with water, aqueous sodium carbonate solution and brine yielded the dienol ether (1.5 g.) as an orange-yellow colored oil. A sample of this material was filtered through a column of alumina (grade III; neutral; 10:1) in benzene-hexane (1:1) mixture. Removal of the solvents in vacuo and crystallization of the pale yellow colored residue from hexane furnished pure (±)-3-[4,4-(2,5-naphthalenedioxy)pentyl]-6aβ-methyl-1,2,3,5,6,6a-hexahydro-cyclopenta-[f][1]benzopyran-7(8H)-one, m.p. 112°-114°.
Anal. Calcd. for C 28 H 30 O 4 : C, 78.11; H, 7.02. Found: C, 78.36; H, 7.30.
Example 34
(±)-3-[4,4-(4,5-Dimethylphenylenedioxy)pentyl]-6aβ-methyl-1,2,3, 5,6,6a-hexahydrocyclopenta[f][1]benzopyran-7(8H)-one
A mixture of (±)-2-(2-diethylaminoethyl)-6-[4,4-dimethylphenylenedioxy)pentyl]-tetrahydropyran-2-ol (11.5 g.), toluene (60 ml.), acetic acid (15.2 ml.) and 2-methylcyclopentane-1,3-dione (3.6 g.) was heated at reflux for 1 hour and then 30 min. more in conjunction with a Dean and Stark water trap. Workup as in Example 33 gave the dienol ether as a brown-red colored solid (11.1 g.). A sample of this material after filtration through alumina (neutral; grade III) yielded pure (±)-3-[4,4-(4,5-dimethylphenylenedioxy)pentyl]-6aβ-methyl-1,2,3,5,6,6a-hexahydrocyclopenta[f][1]benzopyran-7(8H)-one on crystallization from hexane, m.p. 125°-127°.
Anal. Calcd. for C 26 H 32 O 4 : C, 76.44; H, 7.90. Found: C, 76.23; H, 7.95.
Example 35
C/D-trans-3-[4,4-(2,3-naphthalenedioxy)pentyl]-6aβ-methyl-1,2,3, 5,6,6a,7,8,9,9a-decahydrocyclopenta[f][1]benzopyran-7β-ol
The crude dienol ether (±)-3-[4,4-(2,5-naphthalenedioxy)-pentyl]-6aβ-methyl-1,2,3,5,6,6a-hexahydro-cyclopenta[f][1]-benzopyran-7(8H)-one (11.7 g.) dissolved in THF (120 ml.) was cooled to 5° and treated, dropwise with sodium-bis-(2-methoxyethoxy)aluminate (Fr. Pat. No. 1,515,582) (7.1 ml; 70 percent w/w in benzene). After stirring for a further 1 hr. at room temperature, ether (500 ml.) was added followed by dilute aqueous sodium hydroxide solution (2N; 100 ml.). The organic phase was washed with brine and dried over MgSO 4 . Removal of the solvents in vacuo gave a glass comprising racemic 3-[4,4-(2,3-naphthalenedioxy)pentyl]-6aβ-methyl-1,2,3,5,6,6a,7,8-octahydrocyclopenta[f][1]benzopyran-7β-ol. This was one major spot on the tlc analysis and showed bands in the ir spectrum (CHCl 3 solution) at 3600 and 3450 (--OH), 1645 (dienol ether) and 1465 cm.sup. -1 (naphthalenedioxy).
The crude material (11.6 g.) was dissolved in THF (200 ml.) containing 5 percent Pd/C (1 g.) and hydrogenated at room temperature and pressure until one mole of hydrogen had been consumed. The solids were filtered off washed well with more THF and the combined filtrates were taken to dryness in vacuo to give product (11.7 g.) as a glass which contained a major amount of C/D-trans-3-[4,4-(2,3-naphthalenedioxy)pentyl]-6aβ-methyl-1,2,3,5,6,6a,7, 8,9,9a-decahydrocyclopenta[f][1]benzopyran-7β-ol.
This material was one major spot on tlc analysis and showed bands in the ir spectrum (film) at 3450 (--OH), 1675 (enol ether) 1470 and 1250 cm.sup. -1 (naphthalenedioxy). The nmr spectrum showed two methyl signals at 80.78 ppm in the ratio of approximately 85:15 indicating the relative amounts of C/D trans and C/D cis material respectively.
Example 36
C/D-trans-3-[4,4-(4,5-dimethylenedioxy)pentyl]-6aβ-methyl1,2,3,5,6,6a,7,8,9,9a-decahydrocyclopenta[f][1]benzopyran-7β-ol
Treatment of the dienol ether (±)-3-[4,4-(4,5-dimethylphenylenedioxy)pentyl]-6aβ-methyl-1,2,3,5,6,6a-hexahydrocyclopenta[f][1]benzopyran-7(8H)-one (9.8 g.) as in Example 35 yielded the crude alcohol racemic 3-[4,4-(4,5-dimethylphenylenedioxy)pentyl]-6aβ-methyl-1,2,3,5,6,6a,7,8-octahydrocyclopenta[f][1]benzopyran-7β-ol (10 g.) as a glass having bands in the ir spectrum at 3600 and 3450 (--OH) and 1645 cm.sup. -1 (dienol ether). Hydrogenation as in Example 35 gave the enol ether C/D-trans-3-[4,4-(4,5-dimethylphenylenedioxy)pentyl]-6aβ-methyl-1,2,3,5,6,6a, 7,8,9,9a-decahydrocyclopenta[f][1]benzopyran-7β-ol (10.4 g.) as a glass.
The nmr spectrum showed the methyl signals centered at 80.74 ppm in an approximate ratio of 70:30 indicating the relative proportions of the C/D trans and C/D cis materials respectively.
Example 37
(±)-6-[3,3-(2,3-Naphthalenedioxy)butyl]-3aβ-methyl-4,5,8,9,9a-9.beta.-hexahydro-1H-benz[e]indene-3,7-(2H,3aH)-dione
A solution of the crude enol ether C/D-trans-3-[4,4-(2,3-naphthalenedioxy)pentyl]-6aβ-methyl-1,2,3,5,6,6a,7,8,9,9a-decahydrocyclopenta[f][1]benzopyran-7β-ol (12.6 g.) in acetone (135 ml.) was treated with dilute aqueous sulfuric acid (13.4 ml; 1N) and left at room temperature for 2 hr. This solution of the crude hemiketal (±)-3-[4,4-(2,3-naphthalenedioxy)butyl]-4-hydroxy-6aβ-methyl-perhydrocyclopenta[f][1]benzopyran-7β-ol was then cooled to 5° and treated over 20 min. with a solution of sodium dichromate-sulfuric acid (34 ml; from 100 g. Na 2 Cr 2 O 7 .2H 2 O; 70.8 ml. H 2 SO 4 conc. made up to 250 ml. with water).
The mixture was then warmed to room temperature and stirred at that temperature for a further 2 hr. Dilute aqueous sodium bisulfate solution was added (100 ml. 5 percent) followed by brine (100 ml.) and the organic materials were isolated with benzene. The combined benzene extracts were washed with an aqueous sodium carbonate solution (5 percent; 2 × 40 ml.) dried over MgSO 4 and taken up to dryness in vacuo. This gave the triketone (±)-4-[3-oxo-7,7-(2,3-naphthalenedioxy)-octyl]-1aβ-methylperhydroindan-1,5-dione (9.6 g.) as an orange colored oil showing bands in the ir spectrum (CHCl 3 solution) at 1740 (cyclopentanone), 1710 (cyclohexanone and straight chain ketone) and 1470 cm.sup. -1 (naphthalenedioxy).
The crude triketone (9.6 g.), dissolved in methanol, was added to a solution of potassium hydroxide (1.44 g) dissolved in more methanol (36 ml.) and heated at reflux for 1 1/2 hr. Glacial acetic acid (2.2 ml.) was added; the solvents were removed in vacuo and the residue was extracted into methylene chloride, washed with brine, aqueous sodium carbonate solution (5 percent) and dried with MgSO 4 . Removal of the solvents in vacuo yielded the crude tricyclic material as a brown powder. Crystallization from chloroform-methanol mixture yielded pure (±)-6-[3,3-(2,3-naphthalenedioxy)butyl]-3aβ-methyl-4,5,8,9,9a,9b-hexahydro-1H-benz[e]indene-3,7-(2H,3aH)-dione (3.9 g.), m.p. 247°-249°.
Anal. Calcd. for C 28 H 30 O 4 : C, 78.12; H, 7.02. Found: C, 77.81; H, 6.87.
Example 38
(±)-6-[3,3-(4,5-dimethylphenylenedioxy)butyl]-3aβ-methyl-4,5,8, 9a,9b-hexahydro-1H-benz[e]-indene-3,7-(2H,3aHO)-dione
The crude enol ether C/D-trans-3-[4,4-(4,5-dimethylphenylenedioxy)pentyl]-6aβ-methyl-1,2,3,5,6,6a,7,8,9,9a-decahydrocyclopenta[f][1]benzopyran-7β-ol (10.4 g.) in analogous fashion to Example 37 was hydrated to give the crude hemiketal (±)- 3-[4,4-(4,5-dimethylphenylenedioxy)butyl]-4-hydroxy-6aβ-methylperhydrocyclopenta[f][1]benzopyran-7β-ol. This compound was oxidized as before to yield the crude triketone (±)-4-[3-oxo-7,7-(4,5-dimethylphenylenedioxy)octyl]-1aβ-methyl-perhydroindan-1,5-dione showing bands in the ir spectrum (CHCl 3 solution) at 1735 (cyclopentanone), 1710 (cyclohexanone and straight chain ketone) and 1485 cm.sup. -1 (phenylenedioxy). Cyclization of the triketone yielded the crude tricyclic material (±)-6-[3,3-(4,5-dimethylphenylenedioxy)butyl]-3aβ-methyl-4,5,8,9,9a,9b-hexahydro-1H-benz[e]-indene-3,7-(2H,3aH)-dione (4.7 g.) as an orange colored oil. Chromatography on 150 g. of silica gel using benzene-ethyl acetate mixtures (9:1 and 17:3) followed by crystallization from ethanol gave pure product (1.37 g.), m.p. 164°-165°.
Anal. Calcd. for C 28 H 32 O 4 : C, 76.44; H, 7.90. Found: C, 76.20; H, 7.75.
Example 39
(±)-6-[3,3-(2,3-Naphthalenedioxy)butyl]-3aβ-methyl-perhydrobenz[e]-indane-3,17-dione
The tricyclic material (±)-6-[3,3-(2,3-napthalenedioxy) butyl]-3aβ-methyl-4,5,8,9,9a,9b-hexahydro-1H-benz[e]indene-3,7(2H,3aH)-dione (3.2 g.) was treated with 5 percent Pd/C (500 mg.) in THF (100 ml.) containing triethylamine (1 ml.) and hydrogenated at room temperature and pressure until one mole of hydrogen had been consumed. The solids were filtered off and the solvents removed in vacuo. Crystallization of a sample from ethanol yielded the saturated diketon, m.p. 190°-195°.
Anal. Calcd. for C 28 H 32 O 4 : C, 77.75; H, 7.46. Found: C, 77.92; H, 7.32.
Example 40
(±)-19-Nor-androst-4-ene-3,17-dione
A. A solution of (±)-6[3,3-(2,3-naphthalenedioxy)butyl)-3aβ-methyl-perhydrobenz[e]-indane-3,17-dione (2 g.) in n-butanol (60 ml.) was treated with dilute aqueous hydrochloric acid (20 ml; 4N) and heated at reflux for 4 hr. The solvents were removed in vacuo and the residue was extracted with ether. After washing the ethereal solution with aqueous sodium carbonate solution (10 percent) and caustic soda solution (1N) the solvents were removed in vacuo. Crystallization of the residue from methylene chloride-isopropyl ether mixture yielded racemic 19-nor-androst-4-ene-3,17-dione (1.06 g.), m.p. 155°-156° identical with authentic material (tlc; ir, uv).
Uv λ max 239 mμ (ε max 17,100); ir bands at 1738 (cyclopentanone) 1665 and 1620 cm.sup. -1 (cyclohexenone).
B. A solution of (± )-6-[3,3-(4,5-dimethylphenylenedioxy) butyl]-3aβ-methyl-4,5,8,9a,9b-hexahydro-1H-benz[e]-indene-3,7-(2H,3aH)-dione (1.22 g.) in THF (50 ml.) containing triethylamine (.5 ml.) and 5 percent Pd/C (300 mg.) was hydrogenated at room temperature and pressure until one mole of hydrogen was consumed. The solids were filtered off and the filtrate was taken to dryness in vacuo. The residue (1.3 g.), consisting of (±)-6-[3,3-(4,5-phenylenedioxy)butyl]-3aβ-methyl-perhydrobenz[e]-indane-3,17-dione which showed bands in the ir (CHCl 3 solution) at 1735 (cyclopentanone), 1705 (cyclohexanone) and 1485 cm.sup. -1 (phenylenedioxy), dissolved in ethanol (30 ml.) was treated with dilute aqueous hydrochloric acid (4N; 10 ml.) and heated under reflux for 4 hr. Removal of the solvents in vacuo and workup as before yielded (±)-19-nor-androst-4-ene-3,17-dione (615 mg.) on crystallization from methylene chloride-isopropyl ether mixture.
This material was again identical with authentic material (m.p., mixed m.p., tlc, ir, and uv spectra).
Uv λ max 239 mμ (ε max 17,000); ir showed bands at 1738 (cyclopentanone), 1665 and 1620 cm.sup. -1 (cyclohexenone).
Example 41
A mixture of pure "Mannich Base" from Example 14 (4.68 g.) acetone (50 ml.), methyliodide (10 ml.) and anhydrous potassium carbonate (6.0 g.) was stirred at r.t. for 18 hr. The precipitate was filtered off, washed well with acetone and the filtrate evaporated to dryness. The resulting residue was mixed with tertiary butyl alcohol (120 ml.), water (30 ml.) and 2-ethylcyclopentane-1,3-dione and refluxed for 24 hr. After cooling, the mixture was evaporated to dryness, diluted with benzene and extracted with saturated oxalic acid solution, saturated sodium bicarbonate solution and water. The aqueous layers were reextracted with benzene and the combined benzene layers were dried over anhydrous sodium sulfate. Filtration and solvent removal afforded a brown oil (4.5 g.). This material was chromatographed on silica gel (300 g.). Elution with benzene-ether 4:1, 2:1, 1:1, 1:2 and 1:4 afforded 3.77 g. of a colorless oil. This material was treated with p-toluenesulfonic acid (370 mg.; monohydrate) at room temperature. After stirring for 30 minutes the mixture was treated with more p-toluenesulfonic acid (370 mg.) and stirred at room temperature for 2 hr. The solution was then extracted with brine, saturated sodium bicarbonate solution and brine again. The aqueous layers were extracted with benzene and the combined benzene layers dried over anhydrous sodium sulfate. Filtration and solvent removal affored 3.32 g. of an oil, which was chromatographed on silica gel (300 g.). Elution with benzene: ether 9:1 and 4:1 afforded 3S,6aS, 3-(4,4-phenylenedioxypentyl)-6aβ-ethyl-1,2,3,5,6,6a-hexaydrocyclopenta[f][1]benzopyran-7(8H)-one, (2.69 g; 60% from Mannich Base) as an oil; [a] D 25 = -117.8° (C= 1.30 in CHCl 3 ).
Example 42
A solution of the product from Example 41 (2.66 g.) in THF (30 ml.; dried over Al 2 O 3 , grade I) was added at 0°-5°C. (within 10 min.) to a mixture of lithium aluminumhydride (520 mg.) in THF (50 ml.), with stirring. The resulting mixture was stirred at room temperature for 1 1/2 hr. and then worked up by careful addition of saturated aqueous sodium sulfate solution. Filtration and solvent removal affored 3S,6aS,3-(4,4-phenylenedioxypentyl)-6aβ-ethyl-1,2,3,5,6,6a,7,8-octahydrocyclopenta[f][1]benzopyran-7β-ol (2.74 g.) as an oil.
Example 43
A solution of the product from Example 42 (2.54 g.) in toluene (90 ml.) was hydrogenated under normal conditions using a palladium catalyst (300 mg.; "AK 4"). The uptake (145 ml.) of H 2 stopped after about 3 hr. The catalyst was filtered off and washed with benzene. Solvent removal gave trans-3S,6aS,3-(4,4-phenylenedioxypentyl)-6aβ-ethyl-1,2,3,5,6,6a,7,8,9,9a-decahydrocyclopenta[f][1]benzopyran-7β-ol as an oil.
Example 44
A mixture of the product from Example 43 (2.8 g.) acetone (26 ml.) and 0.5N sulfuric acid (2.6 ml.) was allowed to stand at room temperature for 2 3/4 hr. The reaction mixture containing trans-3S,6aS,3-(4,4-phenylenedioxypentyl)-6aβ-ethyl-perhydrocyclopenta[f][1]benzopyran-4,7β-diol was then cooled to 0°C. and treated with freshly prepared Jones Reagent (6.7 ml.). After addition, the mixture was stirred at room temperature for 4 hr., then diluted with benzene and the resulting mixture extracted with water, saturated sodium bicarbonate solution and brine. The aqueous layers were reextracted with benzene and the combined benzene layers dried over anhydrous sodium sulfate. Filtration and solvent removal afforded trans-1aS,4-(3-oxo-7,7-phenylenedioxyoctyl)-1aβ-ethyl-perhydroindan-1,5-dione (2.0 g.) as a brown oil.
Example 45
A solution of the product from Example 44 (2.0 g.) in methanol (6.5 ml.) was treated with a solution of potassium hydroxide (210 mg.) in methanol (13.5 ml.) and then refluxed with stirring for 1 1/2 hr. After cooling, the mixture was diluted with benzene and extracted with water, 0.5 N-hydrochloric acid, saturated sodium bicarbonate solution and brine. The aqueous layers were reextracted with benzene and the combined benzene layers dried over anhydrous sodium sulfate. Filtration and solvent removal afforded trans-anti-3aS,6-(3,3-phenylenedioxybutyl)-3aβ-ethyl-4,5,8,9,9a,9b-hexahydro-1H-benz[e]inden-3,7(2H, 8H)-dione (1.46 g.) as an oil.
Example 46
A solution of the product from Example 45 (1.46 g.) in ethanol (42 ml.) and triethylamine (2.0 ml.) was hydrogenated under normal conditions using a palladium catalyst (300 mg.; "AK 4"). The uptake (88 ml.) of H 2 stopped after 5 hr. The catalyst was filtered off and washed with ethanol. Solvent removal afforded trans-anti-trans-3aS,6-(3,3-phenylenedioxybutyl)3aβ-ethyl-4,5,5a,6,8,9,9a,9b-octahydro-1H-benz[e]-inden-3,7(2H,8H)-dione (1.39 g.) as an oil.
Example 47
A solution of the product from Example 46 (1.39 g.) in ethanol (39 ml.) and 2N hydrochloric acid (19 ml.) was refluxed for 4 hr. After cooling, the mixture was concentrated in vacuo, then diluted with benzene and extracted with water, 10% aqueous sodium carbonate solution, 10% aqueous sodium hydroxide solution and brine. The aqueous layer was reextracted with benzene and the combined benzene layers dried over anhydrous sodium sulfate. Filtration and solvent removal afforded 1.0 g. of an oil. This material was chromatographed on alumina (grade III, 100 g.). The column was prepared in a hexane-benzene mixture 4:1. Elution with hexane-benzene 1:9, benzene along and benzene-ether 9:1 afforded 550 mg. of a semi-crystalline product. This material was crystallized from isopropyl ether-hexane at 0°C. to afford d-(+)-13β-ethylgon-4-en-3,17-dione, 337.4 mg., as colorless crystals. An optically pure sample was obtained by fractional recrystallization of the above sample from ethanol and methanol. The analytically pure sample had a m.p. of 176.5°-178°C. and [α] D 25 = +98.13° (C= 1.0374, CHCl 3 ).
Calcd. for C 19 H 26 O 2 : C, 79.68; H, 9.15 (286.40) Found: C, 79.89; H, 9.26. Uv max (e) at 239 mμ, ε16250; ir CHCl 3 showed absorptions at 1740 cm.sup. -1 (cyclopentanone), 1660 and 1620 cm.sup. -1 (unsaturated ketone). Nmr (A 60, CDCl 3 ) triplet, 3 protons C 18 -CH 3 , centered at δ0.80, J= 8 cps; singlet, 1 proton C 4 -H, at δ5.85. | The intermediates and processes of this disclosure provide a new stereo-specific total synthesis of steroidal materials having known valuable pharmacological properties. A fundamental feature of this disclosure is the utilization of aryl ketals, preferably phenylenedioxy ketals derived from catechol as protective groups for oxo moieties in the polycyclic intermediates used in the aforesaid total synthesis. | 2 |
BACKGROUND OF THE INVENTION
[0001] This invention relates to an improved inner tie rod tool useful for removal and replacement of inner tie rods, particularly of the type which include a cylindrical inner end.
[0002] U.S. Pat. No. 5,287,776 for an Inner Tie Rod Tool, incorporated herewith by reference, discloses a tool to facilitate the removal and replacement of inner tie rods for the steering control system of a vehicle. That is, many vehicles are equipped with a rack and pinion steering control system which is connected by means of tie rods to the running gear for the front wheels of the vehicle. The steering wheel of the vehicle may thus be turned or rotated to effect rotation of a pinion, thereby driving a rack and consequently moving the tie rods to effect movement of the front wheels of the vehicle and thereby control the direction of vehicle movement.
[0003] Servicing and repair of the steering control system often requires removal and replacement of the tie rods, including the inner tie rods which effectively connect the rack or other steering mechanism to the front wheels of the vehicle. The tie rods typically include a rod with a collar at one end. The collar may include an internal threaded connection for attachment of the tie rod to the steering system and external flats for engagement by a wrench type tool to rotate the tie rod for removal or installation. U.S. Pat. No. 5,287,776 describes, in general, various types of tie rod constructions of this type and a tool for effecting their removal.
[0004] With some vehicle steering systems, the utilization of a hexagonal nut or flats associated with the collar of the inner tie rod are omitted and in their place the tie rod is provided with a cylindrical collar. Removal of the inner tie rod using a tool of the type disclosed in U.S. Pat. No. 5,287,776, thus becomes difficult and perhaps impractical.
[0005] Various solutions for removal of such alternative tie rod constructions have been proposed. For example, KD Tools makes an inner tie rod tool, Model 3312, designed for removal and installation of inner tie rods on many General Motors and some Chrysler products. This tool is designed to be used on tie rods having a complete hexagonal or just two flats on the inner end. The tool includes an annular end collar which is generally cylindrical and a single set screw. Northstar Manufacturing Company makes a similar product, part number 88-7301 identified as a universal inner tie rod socket. It utilizes a collar which engages the end of a tie rod by a pair of set screws.
[0006] Thus, the variety of tools available for the removal and replacement of inner tie rods is significant. Nonetheless, such tools are not necessarily satisfactory for removal of tie rods having round or cylindrical ends because such tie rods do not have any flat surfaces that can be engaged to facilitate their removal and replacement by wrench type devices. For example, the KD Tool described utilizes a large annular collar and single set screw in order to be compatible with numerous types of inner tie rods. Because of the size of the annular collar, the tool may be off center during use, thereby resulting in difficulty when seeking to effect tie rod removal inasmuch as the tool is not concentric with respect to the tie rod that is to be removed. This failure in alignment may cause parts to bind, for example.
[0007] Thus, there has developed the need to develop an inner tie rod tool especially useful for removal of tie rods wherein the tie rods do not necessarily include a flat end wrench engageable surface and wherein the tie rods typically would include a cylindrical or round end surface.
SUMMARY OF THE INVENTION
[0008] Briefly, the present invention comprises a tool for removal and replacement of inner tie rods which have a generally cylindrical end. The tool includes an elongate, hollow, cylindrical tube having a generally uniform internal diameter. A butt plate with a socket drive opening is attached at a first end of the tube for driving by means of a socket wrench. An annular collar is attached to the opposite end of the tube. The annular collar includes at least three radial threaded passages, each receiving a single headless set screw. The passages are arrayed at approximately 45° from each other. The location or array of the fastening passages and fasteners in combination with the annular collar enable placement of the tool upon tie rods having cylindrical outer engagement surfaces and enables generally concentric arrangement of the tool on the tie rod and facilitates ease of removal of such inner tie rods.
[0009] Thus, it is an object of the invention to provide an improved inner tie rod removal tool;
[0010] It is a further object of the invention to provide a tool for removal of inner tie rods having a generally cylindrical inner end;
[0011] Another object of the invention is to provide inexpensive yet highly efficient, inexpensive and easy to use inner tie rod removal tool.
[0012] These and other objects, advantages and features of the invention will be set forth in the detailed description which follows.
BRIEF DESCRIPTION OF THE DRAWING
[0013] In the detailed description which follows, reference will be made to the drawing comprised of the following figures:
[0014] FIG. 1 is an isometric view of an embodiment of the inner tie rod tool of the invention;
[0015] FIG. 2 is an exploded side plan view of the inner tie rod tool of FIG. 1 ;
[0016] FIG. 3 is an end view of the collar of the tie rod tool of FIG. 1 ;
[0017] FIG. 4 is a side view of the collar of FIG. 3 ;
[0018] FIG. 5 is an end view of the tool of FIG. 1 as viewed from the butt plate end;
[0019] FIG. 6 is a side cross sectional view of the tool of FIG. 1 ;
[0020] FIG. 7 is an isometric view of the tool of FIG. 1 placed over an inner tie rod having a cylindrical inner end; and
[0021] FIG. 8 is an isometric view of the inner tie rod tool of FIG. 7 attached to the inner end of a tie rod.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0022] Referring to the Figures, the tool of the present invention is comprised of three basic parts that are assembled or welded together for use in combination with a set of three headless, set screws. Thus, the tool includes a generally cylindrical tube 10 having a longitudinal axis 12 , a length in the axial direction in a range of twelve to twenty five inches and a cylindrical diameter in the range of one and one half to two inches. A typical axial dimension of such a tube is approximately thirteen inches. A butt plate 14 is welded at one end of the tube 10 . The butt plate 14 includes a polygonal socket opening 16 aligned axially on the tube 10 .
[0023] The opposite end of the tube 10 includes a cylindrical annular collar 18 welded thereto. The annular collar 18 includes three set screw threaded passages 20 , 22 and 24 , arranged radially and extending through the collar 18 . The collar 18 thus includes a cylindrical passage 26 with the set screw passages 20 , 22 and 24 extending from the outside face of the collar 18 to the interior passage 26 . Threaded set screws such as set screw 28 , which are headless and which include a polygonal recess 30 for receipt of an Allen wrench, for example, are threadably inserted into the separate threaded passageways 20 , 22 and 24 .
[0024] In the preferred embodiment, the internal diameter of the passageway 26 of the collar 18 is matched closely to the outer cylindrical dimension of the cylindrical end 32 of the tie rod 33 which is to be engaged, for example, as depicted in FIG. 7 . The collar 18 , tube 10 and butt plate 14 are thus all aligned co-axially and the tool can therefore be placed over the inner tie rod 33 of a vehicle with the collar 18 positioned over the cylindrical end 32 of the tie rod 33 so that the set screws, such as set screw 28 , can be tightened against the outer surface of the cylindrical end 32 of inner tie rod 33 .
[0025] As depicted in FIG. 4 , the collar 18 includes a through passage 26 which is comprised of a first inner end counterbore 27 connected to an opposite end counterbore 29 to define the throughbore or passage 26 . The inner end counterbore 27 diameter is closely matched to the outer diameter of the tube 10 and is greater than the diameter of the inner end counterbore 29 . Thus, there is a transition or junction or ridge 31 connecting the counterbores 27 and 29 . The ridge 31 limits the distance of insertion of the tube 10 into the collar 18 and precludes the tube 10 from being positioned inwardly in a manner that would interfere with the set screw passages 20 , 22 and 24 . Thus, the set screw passages 20 , 22 and 24 each are directed radially into a portion of the inside counter bore 29 .
[0026] The diameter of the inner counterbore 29 is closely matched to the outside diameter of the cylindrical end 32 of the tie rod 33 . It exceeds the outside diameter thereof, but is closely matched so that it can slide thereon, enabling the set screws 28 to be tightened against the outer end of the tie rod 33 in a manner whereby the tool remains generally co-axial with the tie rod.
[0027] As another feature of the invention, the set screws 28 are arrayed at approximately 45° from one another within a cumulative range of about 90° maximum spacing of the screws 28 . In this manner, the three set screws in combination, provide a tight grip on the tie rod 33 and simultaneously are positioned in a manner which will enable a mechanic to easily access those screws 28 . Thus, the set screws 28 are not opposite of each other. Rather, they are within an approximate 90° section of the cylindrical collar 18 .
[0028] These dimensional features and characteristics enable a mechanic or tradesman adequate benefit from the use of the tool in confined spaces where inner tie rods are located in motor vehicles. Thus, in the preferred embodiment, the passages or threaded openings for the set screws 28 are arranged at spaced angular relationship of 45°±5°, preferably. Also, the set screws 28 are headless in order to enable the screws 28 to be threaded into the appropriate passageways without limiting their radial inward movement and without projecting unnecessarily outwardly from the collar 18 and so as to enable an Allen wrench 90 access to the set screws. FIG. 8 depicts a typical Allen wrench 90 that would be used with the set screws that are contemplated with respect to the tool.
[0029] Variations of the tool are considered to be within the scope of the invention, including the dimensional variations associated with the component parts, the shape of the polygonal opening in the butt plate and other similar variations. The invention is therefore limited only by the following claims and equivalents thereof. | A tool for removal of inner tie rods having a generally cylindrical end includes a hollow tube with a butt plate at one end and an annular collar at the opposite end for attachment to the tie rod by means of three set screws arranged within an angular range of approximately 90°, wherein the tool collar is designed to provide for ease of assembly of the tool by joining the tube to the annular collar. | 1 |
BACKGROUND OF THE INVENTION
[0001] This invention relates to a silent chain used for power transmission, in applications such as the timing drive of automobiles or motorcycles, or as a chain drive in a general purpose engine, a diesel engine or an industrial machine or the like. More specifically, the invention relates to a silent chain used as a timing chain in an engine.
[0002] An example of a conventional silent chain a bush-type silent chain 1 is shown in FIGS. 3 (A) and 3 (B). In this silent chain 1 , guide plates 2 , link assemblies 3 and intermediate link plates 6 are disposed adjacent one another in the direction of the width of the chain, but shifted longitudinally so that they are interleaved. The interleaved members are articulably connected with one another by connecting pins 7 .
[0003] The guide plates 2 do not have teeth, but each guide plate has a pair of pin holes 2 a as shown in FIG. 4. Each link assembly 3 comprises two inner link plates 4 each having a pair of teeth 4 a, which mesh with the teeth of a sprocket, a pair of bushing holes 4 b, and a pair of bushings 5 , each press-fit into a bushing hole 4 b, as shown in FIGS. 5 (A) and 5 (B). In the link assembly 3 , the two inner link plates 4 are integrally connected and fixed to each other by two bushings 5 . Further, each intermediate link plate 6 includes a pair of teeth 6 a, which mesh with the teeth of a sprocket, and a pair of pin holes 6 b, as shown in FIG. 6.
[0004] In the inner link plate 4 , as shown in FIG. 5(A) and FIG. 7, a pair of teeth 4 a are formed, each having an outside surface portion 4 c and an inside surface portion 4 d, a pair of bushing holes 4 b, into each of which a bushing 5 is press-fit and fixed, a back surface portion 4 e formed on the side opposite to the side where the pair of teeth 4 a is formed, and a pair of shoulder portions 4 f, each of which connects an outside surface portion 4 c to the back surface portion 4 e. The broken line P in FIG. 7 is a pitch line, which passes through the centers of the bushing holes 4 b.
[0005] In the particular chain shown in FIG. 3(A), two intermediate link plates 6 are disposed centrally with respect to the width direction of the chain, link assemblies 3 are disposed on both outer sides of the intermediate link plates 6 , and the guide plates 2 are disposed on both of the outermost sides of the chain. These elements are longitudinally shifted with respect to one another, and thereby interleaved, and are articulably connected to one another by connecting pins 7 . In this case, the connecting pin 7 is press-fit into and fixed to the pin holes 2 a of the guide plates 2 on both outermost sides in the chain, and in the intermediate link plates 6 , the connecting pin 7 can extend through the pin holes 6 b with play, or can be press-fit and fixed into the pin hole 6 b.
[0006] Since the link assembly 3 is composed of plural link plates 4 , the problem arises that, if the inner link plates are not light in weight, the weight of the silent chain becomes excessive. Further, the rigidity of the teeth of the inner link plates is high. Thus, when the chain meshes with the teeth of a sprocket during operation, tooth surfaces of each inner link plate collide with tooth surfaces of the sprocket and the collision shock is dispersed to the entire inner link plate, generating meshing noises of large amplitude.
[0007] In the inner link plates 4 , which form the link assembly 3 , the bushing 5 is press-fit into, and fixed to, the bushing hole 4 b. Thus, the bushing hole 4 b, formed in the inner link plate 4 , is a size larger than the pin hole 6 b in the intermediate link plate 6 . As a result, the distance between the bushing hole 4 b and the adjacent outer side portion of the inner link plate 4 becomes smaller than the corresponding distance in the intermediate link plate 6 . In this case, as shown in FIG. 7, the shortest distance k′ between the bushing hole 4 b and the outside surface portion 4 c, and the shortest distance l′ between the bushing hole 4 b and the inside surface portion 4 d are comparatively small. However, the shortest distance w′ between the bushing hole 4 b and the tip of the tooth of the inner link plate is still relatively large. Accordingly, the distances l′, k′ and w′ become unbalanced.
[0008] When the bushing 5 is press-fit into the bushing hole 4 b in the inner link plate 4 to form a link assembly, the inner link plate 4 is usually deformed in the areas where the distance between the bushing hole 4 b and the outer side portion is small. Accordingly, strain is generated in the inner diameter of the press-fit bushing 5 . Since the back surface portion 4 e and the shoulder portions 4 f of the inner link plate 4 have no direct relationship to the meshing of the link plate teeth with the teeth of a sprocket, it is possible to suppress the strain generated in the inner diameter of the press-fit bushing by increasing the shortest distance m′ between the bushing hole 4 b, and the back surface portion 4 e and the shortest distance n′ between the bushing hole 4 b, and the shoulder portions 4 f. However, in the teeth 4 a, the distances k′ and l′ cannot be correspondingly increased without affecting the meshing relationship between the teeth 4 a and the teeth of the sprocket. Thus, when the distances k and l are small, and the distance w′ is large, the inner diameter of the press-fit bushing 5 has different degrees of deformation in the areas corresponding to the distances k′ and l′ and the area corresponding to the distance w′. As a result nonuniform strains are generated, and the inside of the bushing deviates from true roundness. This problem arises because the relationships between the shortest distances and the plate thickness of the inner link plate have not been noted. Thus, the distances k′ and l′ may be too small compared to the plate thickness of the inner link plate. However, these problems can arise even when the plate thickness is increased.
[0009] When the roundness of the inner diameter of the bushing press-fit into the bushing hole deteriorates, if the link assembly is incorporated into a chain, the interfacial pressure between the surface of the connecting pin and the inner periphery of the bushing becomes nonuniform, or the connecting pin makes contact with the inner periphery of the bushing only on one side. Consequently, wear of the connecting pin and bushing, and resulting wear elongation of the chain are both accelerated.
SUMMARY OF THE INVENTION
[0010] Accordingly, a general object of this invention is to overcome the problems associated with the above-described conventional silent chain.
[0011] A more specific object of the invention is to provide a silent chain in which wear of the connecting pins and bushings, and wear elongation of the chain can be suppressed.
[0012] According to one aspect of the invention, the silent chain comprises a link assembly including at least two inner link plates, each link plate having a pair of teeth and a pair of bushing holes, the link plates being connected and fixed to one another by a pair of bushings, each said bushing being press-fit into bushing holes of all of said link plates of the link assembly, wherein each of the teeth of the inner link plates has a through-hole approximately in its center.
[0013] According to the invention, the deformation of the inside of a press-fit bushing can be made more uniform compared to the deformation in the case of conventional inner link plate lacking the through-holes. Accordingly, deviation from roundness in the inside of the bushing can be prevented.
[0014] Further, the through-holes reduce the weight of the inner link plates, and as a result, a weight reduction of the a reduction in the overall weight of the silent chain can be realized. Because of this weight reduction, when the silent chain meshes with the sprocket teeth the shock energy due to the collision between the tooth faces of the inner link plates and sprocket is reduced, so that the occurrence of high-amplitude meshing noises can be prevented, and wear of the tooth faces can be suppressed.
[0015] In the silent chain according to the invention, each tooth of the pair of teeth of an inner link plate is adjacent a bushing hole and includes an outside surface portion and an inside surface portion. The inner link plate is preferably formed so that the shortest distance between the bushing hole and the through-hole, the shortest distance between the bushing hole and the outside surface portion, and the shortest distance between the bushing hole and the inside surface portion, are substantially equal, and the respective shortest distances are equal to, or greater than, the plate thickness of the inner link plate. When the above-mentioned relationships between the shortest distances and the plate thickness are satisfied, deformation of the inner link plate during press-punching can be prevented. Moreover, reduction in vertical accuracy of the bushing hole with respect to the inner link plate, thus the reduction in vertical accuracy of the press-fit bushing therewith can be prevented. Further, in the press-fit bushings, deformation of the inner peripheries of the bushings becomes nearly uniform, so that deviations from roundness of the inner peripheries of the bushings can be prevented. As a result, since biased contact between the connecting pins and the inner peripheries of the bushings can be prevented, and at the same time interfacial pressure between the connecting pins and the inner peripheries of the bushings becomes uniform, wear of the connecting pins and bushings, and wear elongation of the chain, can be suppressed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] Preferred embodiments of the invention will now be described in detail with reference to the accompanying drawings, in which:
[0017] FIGS. 1 (A) and 1 (B) show an inner link plate according to a first embodiment of the invention, FIG. 1(A) being a cross-sectional view and FIG. 1(B) being a side elevational view;
[0018] [0018]FIG. 2 is a side view of an inner link plate according to a second embodiment of the invention;
[0019] FIGS. 3 (A) and 3 (B) show a conventional silent chain, FIG. 3(A) being a fragmentary plan view partially in cross-section, and FIG. 3(B) being a fragmentary side view;
[0020] [0020]FIG. 4 is a side view of a guide plate;
[0021] FIGS. 5 (A) and 5 (B) show a link assembly, FIG. 5(A) being a side view, and FIG. 5(B) being a cross-sectional view;
[0022] [0022]FIG. 6 is a side view of an intermediate link plate;
[0023] [0023]FIG. 7 is a side view of a conventional inner link plate; and
[0024] [0024]FIG. 8 is a graph showing results of a test comparing the elongation of silent chains in accordance with the invention with the elongation of a conventional chain.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0025] The following description is merely exemplary in nature and is in no way intended to limit the invention or its application or uses.
[0026] The first embodiment of the invention will be described with reference to FIG. 1. A silent chain of the invention is substantially the same as the conventional silent chain shown in FIGS. 3 to 7 except that the link assembly of the invention is different from a conventional link assembly. Accordingly, no separate drawing or explanation need be provided to show or describe the structure of the chain in accordance with the invention. The corresponding members of the silent chain of the invention and the conventional silent chain are denoted by the same reference numerals and the description thereof will be omitted.
[0027] As in the case of the conventional silent chain, the silent chain in accordance with the first embodiment of the invention comprises, two intermediate link plates 6 disposed centrally with respect to the width direction of the chain, two link assemblies 3 respectively disposed on both outer sides of the intermediate link plates 6 , and two guide plates 2 respectively disposed on the outermost sides of the link assemblies 3 . The members are combined in interleaved relationship and articulately connected to one another by a connecting pin 7 . The guide plate 2 does not have teeth, but has a pair of pin holes 2 a. The intermediate link plate 6 includes a pair of teeth 6 a, which mesh with the teeth of a sprocket, and a pair of pin holes 6 b.
[0028] The link assembly 3 comprises, as in the conventional link assembly, two inner link plates, each having a pair of teeth, which mesh with the teeth of a sprocket, a pair of bushing holes, and a pair of bushings 5 , each press-fit into bushing holes in both link plates. In the link assembly 3 , the two inner link plates are integrally connected and fixed to each other by the two bushings 5 .
[0029] [0029]FIG. 1 shows an inner link plate 14 , which forms a link assembly according to the invention. A pair of teeth 14 a is formed on the inner link plate 14 , as shown in FIG. 1. Each tooth has an outside surface portion 14 c and an inside surface portion 14 d. A pair of bushing holes 14 b are provided, into each of which a bushing 5 is press-fit and fixed. The link plate 14 has a back surface portion 14 e formed on the side opposite to the side on which the pair of teeth 14 a is formed, and a pair of shoulder portions 14 f, each of which connects an outside surface portion 14 c with the back surface portion 14 e. Each shoulder portion 14 f is in the form of an arc, which is substantially concentric with a bushing hole 14 b.
[0030] Through-holes 14 g are formed substantially in the centers of teeth 14 a of the inner link plate 14 to achieve a weight reduction of the inner link plate. In FIG. 1, j is the shortest distance between the bushing hole 14 b and the through-hole 14 g, k is the shortest distance between the bushing hole 14 b and the outside surface portion 14 c, and l is the shortest distance between the bushing hole 14 b and the inside surface portion 14 d. The through-hole 14 g is of a substantially triangular shape, corresponding to the shape of the tooth 14 a, and formed so that the shortest distances j, k, and l are substantially equal to one another, and related to the plate thickness t of the inner link plate 14 , so that j k l·t.
[0031] When the inner link plate 14 is formed as described above, since strain is better dispersed than in the case where through-holes are not provided, the bushing 5 , which is press-fit into the bushing hole 14 b, has a substantially uniform deformation in its inner periphery at the locations adjacent to the positions of the shortest distances j, k, and l. Thus, deviation from roundness in the inner surface of the bushing is prevented. Accordingly, biased contact between the connecting pin and the inner periphery of the bushing is prevented and at the same time, interfacial pressure between the connecting pin and the inner periphery of the bushing becomes uniform, so that wear of the connecting pin and bushing can be prevented. As a result, wear elongation of the silent chain incorporating the link assembly is prevented. Further, since the shortest distances j, k and l are equal to or greater than the plate thickness t, deformation of the plate in the process of press-punching is prevented, and reduction in vertical accuracy of the bushing hole with respect to the plate is also prevented.
[0032] The second embodiment of the invention will be described with reference to FIG. 2. The silent chain in the second embodiment comprises, as in the silent chain of the first embodiment, two intermediate link plates 6 , two link assemblies 3 respectively disposed on both outer sides of the intermediate link plates 6 , and two guide plates 2 respectively disposed on the outermost sides of the link assemblies 3 . The members are combined in interleaved relationship and articulately connected to one another by a connecting pin 7 .
[0033] The link assembly 3 comprises, as in the conventional link assembly, two inner link plates, each having a pair of teeth, which mesh with the teeth of a sprocket, a pair of bushing holes, and a pair of bushings 5 , each press-fit into bushing holes in both link plates. In the link assembly 3 , the two inner link plates are integrally connected and fixed to each other by the two bushings 5 .
[0034] Circular through-holes 24 g are formed in the approximate centers of the teeth 24 a of the inner link plate 24 , as in the first embodiment. Each through-hole 24 g is formed so that the shortest distances j, k, and l are substantially equal to each other and equal to or greater than the plate thickness t of the inner link plate 24 . That is j k l·t, where j is the shortest distance between the bushing hole 24 b and the through-hole 24 g, k is the shortest distance between the bushing hole 24 b and the outside surface portion 24 c, and l is the shortest distance between the bushing hole 24 b and the inside surface portion 24 d.
[0035] When the inner link plate 24 is formed as described above, since strain is better dispersed than in the case of a link plate lacking through-holes, the bushing 5 , which is press-fit into the bushing hole 24 b exhibits a substantially uniform degree of deformation in the inner periphery of the bushing 5 at the locations adjacent the positions, of the distances j, k, and l. Thus, deviation from roundness in the inner surface of the bushing is prevented. Accordingly, biased contact between the connecting pin and the inner periphery of the bushing is prevented and at the same time, interfacial pressure between the connecting pin and the inner periphery of the bushing becomes uniform, so that wear of the connecting pin and bushing can be prevented. As a result, wear elongation of the silent chain incorporating the link assembly is prevented.
[0036] The link assembly preferably comprises at least two link plates. In still another embodiment of the invention, not shown in the drawings, the link assembly may comprise three or more link plates instead of two link plates. Further, in a silent chain according to the invention, instead of two link assemblies in the width direction of the chain, three or more link assemblies may be disposed in the width direction. Further, one or a plurality of intermediate link plates may be provided, and intermediate link plates may be disposed at a plurality of positions.
[0037] Still another type of silent chain in accordance with the invention may have a guide plate 2 inside in the width direction of the chain, for example a centrally located guide plate. In this case, link assemblies 3 may be disposed on both sides of the guide plate 2 , and outer link plates 6 may be disposed on the outermost sides of the respective link assemblies 3 . The members are connected to one another in an interleaved relationship by a connection pin 7 . In this case, when the silent chain is used as a transmission device with the silent chain wound around a sprocket, the sprocket will have an annular groove in its outer periphery for receiving the centrally located guide plate.
[0038] [0038]FIG. 8 shows the results of test comparing the silent chains according to the first and second embodiments of the invention, having substantially triangular and circular through-holes, respectively, and a conventional silent chain having link plates of the type shown in FIG. 7. The silent chains in accordance with the invention differed from each other, and from the conventional chain only in the configurations of the inner link plates of the link assembly.
[0039] In the inner link plate, the intermediate link plate, and the guide plate in each of the three silent chains, the pitch measured between the centers of the pin holes (or the bushing holes) was about 9.525 mm. The diameter of the connecting pins was about 4.5 mm or less. The length of the bushings was about 4.5 mm. The bushing wall thickness was about 0.7 mm. The inner bushing diameter was about 4.5 mm or more. The clearance C, i.e., the total distance between the ends of the bushing and the guide plate and intermediate link plate, was about 0.1 mm.
[0040] In the inner link plates of the link assemblies, in accordance with the first and second embodiments of the invention, the distances k, l, m′, n′, and j, and the plate thickness t were as follows:
l: about 1.4 mm, t; about 1.3 mm, k: about 1.35 mm, n; about 1.6 mm, j; about 1.35 mm m: about 1.6 mm,
[0041] In the conventional product, the distances k′, l′, m′, n′, and the plate thickness t ware as follows:
[0042] k′: about 1.35 mm, l′ about 1.4 mm,
[0043] m′: about 1.6 mm, n′ about 1.6 mm, t: about 1.3 mm.
[0044] j is the shortest distance between the bushing hole and the through-hole, k and k′ are the shortest distances between the bushing hole and the outside surface portion, l and l′ are the shortest distances between the bushing hole and the inside surface portion, m and m′ are the shortest distances between the bushing hole and the back surface portion and n and n′ are the shortest distances between the bushing hole and the shoulder portion.
[0045] The test conditions were as follows: The sprocket: 21 NT× 42 NT. The chain speed: about 19 m/s. The chain tension: about 1.8 kN. The chain lengths were measured over time after running the chain with continued lubrication. The elongation ratio compares the elongated length of the chain after the test to the initial length of the chain. As can be seen from FIG. 8, the silent chains in accordance with the first and second embodiments of the invention had a significantly superior elongation ratio compared with the elongation ratio exhibited by the conventional silent chain.
[0046] Obviously, various minor changes and modifications of the invention are possible in the light of the above teaching. It is therefore to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described. | In a silent chain, wear of the connecting pins and bushings, and wear elongation of the chain itself, are suppressed by the formation of through holes in the approximate centers of the teeth of toothed link elements for relieving strains in the inner peripheries of the bushings due to press-fitting of the bushings into the toothed link elements. The shortest distances between the bushing hole on the one hand, and the through-hole, the outside tooth surface and the inside tooth surface, on the other hand, are made substantially equal to one another. The through holes also reduce the weights of the individual link elements and contribute to a reduction in overall weight of the chain. | 5 |
TECHNICAL FIELD
[0001] This specification generally relates to systems for and methods of hydraulic activation of a mechanically operated tool positionable in a bottom hole assembly used in drilling a wellbore.
BACKGROUND
[0002] During well drilling operations, a drill string is lowered into a wellbore. In some drilling operations, (e.g. conventional vertical drilling operations) the drill string is rotated. The rotation of the drill string provides rotation to a drill bit coupled to the distal end of a bottom hole assembly (“BHA”) that is coupled to the distal end of the drill string. The bottom hole assembly may include stabilizers, reamers, measurement-while-drilling (“MWD”) tools, logging-while-drilling (“LWD”) tools and other downhole equipment as known in the art. In some drilling operations, (e.g. if the wellbore is deviated from vertical), a downhole mud motor may be disposed in the bottom hole assembly above the drill bit to rotate the bit instead of rotating the drill string to provide rotation to the drill bit.
[0003] In some drilling operations, in order to pass through the inside diameter of upper strings of casing already in place in the wellbore, often times the drill bit will be of such a size as to drill a smaller gage hole than may be desired for later operations in the wellbore. It may be desirable to have a larger diameter wellbore to enable running further strings of casing and allowing adequate annulus space between the outside diameter of such subsequent casing strings and the wellbore wall for a good cement sheath. A borehole opener (“reamer”) may be included in the drill string to increase the diameter of the (“open”) borehole.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] FIG. 1 is a diagram of an example bottom hole assembly featuring a near-bit reamer.
[0005] FIG. 2A is a side view of the lower end of the bottom hole assembly illustrating the near-bit reamer coupled to a drill bit.
[0006] FIG. 2B is a cross-sectional side view of a portion of the near-bit reamer of FIG. 2A .
[0007] FIGS. 3A-3C are cross-sectional perspective, top, and side views of a drill bit fitted with a grate actuation assembly.
[0008] FIGS. 4A-4C are sequential diagrams of a technique for using deformable drop balls to activate a near-bit reamer.
[0009] FIG. 5 is a flowchart illustrating a method of activating a near-bit reamer that involves creating a temporary flow restriction upstream of the near-bit reamer.
[0010] FIG. 6 is a flowchart illustrating a method of activating a near-bit reamer that involves introducing a highly viscous pill fluid to the bottom hole assembly.
[0011] FIG. 7 is a cross-sectional perspective view of a first example filter actuation assembly.
[0012] FIGS. 7A-7B are sequential diagrams illustrating operation of the first example filter actuation assembly.
[0013] FIG. 8A is an exploded diagram illustrating a second example of a filter actuation assembly.
[0014] FIGS. 8B and 8C are perspective and cross-sectional side views of the second example filter actuation assembly in an assembled form.
[0015] FIGS. 8D-8F are sequential diagrams illustrating operation of the second example filter actuation assembly.
[0016] FIG. 9 is a cross-sectional perspective view of a third example of a filter actuation assembly.
[0017] FIG. 10A is a cross-sectional side view of a lower section of a bottom hole assembly featuring an activation bushing.
[0018] FIG. 10B is a cross-sectional perspective view of the activation bushing of FIG. 10A .
[0019] FIGS. 10C and 10D are sequential diagrams illustrating operation of the activation bushing of FIGS. 10A and 10B .
[0020] Some of the features in the drawings are enlarged to better show the features, process steps, and results.
DETAILED DESCRIPTION
[0021] The present disclosure includes methods and devices for hydraulic activation of a mechanically operated bottom hole assembly tool. In some implementations a near-bit borehole opener/enlargement tool, also known as a near-bit reamer (“NBR”), is disposed on the distal end (or “lower end”) of a tool string proximal to the drill bit. For example, the present disclosure relates to devices that may be used to activate cutting blocks of a borehole opener tool by adjusting the hydraulic pressure of the drilling fluid within a bottom hole assembly.
[0022] FIG. 1 is a diagram of an example bottom hole assembly 10 . The bottom hole assembly 10 is the lower component of a drill string 12 suspended from a drilling rig (not shown). In some implementations, the upper end of the bottom hole assembly 10 includes a conventional under reaming tool 14 (e.g., a Halliburton model XR Reamer or UR-type conventional under reaming tool). Below the conventional under reaming tool 14 is positioned a measurement-while-drilling (“MWD”) and/or a logging-while-drilling (“LWD”) tool string section 16 . The MWD/LWD tool string section 16 is positioned below the conventional under reaming tool 14 so that the enlarged borehole will not degrade performance of the MWD/LWD tools or the associated stabilizer elements 18 . Below the MWD/LWD tool string section 16 is a rotary steerable system (“RSS”) tool string 20 (e.g., Halliburton's Geo Pilot System) designed to facilitate directional drilling. Similar to the MWD/LWD tool string section 16 , the RSS tool string 20 is located below the conventional under reaming tool 14 in order to ensure its proper functioning. The lower end of the bottom hole assembly 10 features an NBR 100 mounted just above the drill bit 22 and below the RSS tool string 20 .
[0023] In the foregoing description of the bottom hole assembly 10 , various items of equipment, such as pipes, valves, fasteners, fittings, articulated or flexible joints, etc., may have been omitted to simplify the description. It will be appreciated that some components described are recited as illustrative for contextual purposes and do not limit the scope of this disclosure.
[0024] FIG. 2A is a side view of the lower end of the bottom hole assembly 10 illustrating the NBR 100 and the drill bit 22 . In this example, the NBR 100 and the drill bit 22 are directly adjacent on the bottom hole assembly 10 . However, other arrangements where the NBR and drill bit are separated by one or more components are also within the scope of the present disclosure. As shown, the NBR 100 includes a plurality of cutting blocks 202 to engage to wall of the surrounding wellbore. The cutting blocks 202 are positioned circumferentially about an elongated body 204 of the NBR 100 . In this example, the NBR 100 includes three cutting blocks 202 located at circumferential intervals of 120°. Of course, any suitable arrangement of cutting blocks may be used in various other embodiments and implementations without departing from the scope of the present disclosure.
[0025] Each of the cutting blocks 202 includes a cutter element 206 disposed on a radial piston 208 disposed inside the elongated body 204 . The cutter elements are initially in a radially-retracted position. When the NBR 100 is actuated, the cutter elements 206 are moved radially outward relative to a central longitudinal axis 212 to contact the wellbore wall. As the NBR 100 is rotated, the cutter elements 206 abrade and cut away the formation, thereby expanding the diameter of the borehole.
[0026] FIG. 2B is a cross-sectional side view of the NBR 100 . As shown, each of the radial pistons 208 includes an anchor plate 216 . The radial pistons 208 are held in place by shear pins 218 such that the cutter elements 206 are in the radially-retracted position. The cutter elements 206 are deployed by hydraulic pressure. That is, when the hydraulic pressure in the body 204 reaches a predetermined threshold, the pressure force acts on the anchor plates 216 to urge the radial pistons 208 radially outward with sufficient force to break the shear pins 218 . Without the shear pins 218 to hold the radial pistons 208 in place, the radial pistons are moved by the hydraulic pressure of the drilling fluid outward toward the wall of the wellbore, deploying the cutter elements 206 . The shear strength rating of the shear pins 218 determines the hydraulic pressure required to activate the NBR 100 . In some examples, the shear pins 218 have shear strength rating of 120 bars, which corresponds to a hydraulic activation pressure for the NBR 100 .
[0027] The NBR 100 further includes biasing members 220 (e.g., disk or coil springs) mounted between the anchor plates 216 of the radial pistons 208 and an outer flange 222 secured to the body 204 . When the hydraulic pressure is reduced to a point where the pressure force against the anchor plates 216 is overcome by the biasing members 220 (e.g., when the flow of drilling fluid sufficiently decreases or ceases entirely), the radial pistons 208 are pulled back such that the cutter elements 206 are returned to the retracted position.
[0028] As described above, the NBR 100 is activated by increasing hydraulic pressure of the drilling fluid beyond a predetermined threshold determined by the shear strength rating of the shear pins 218 . For example, in some implementations, the NBR may be activated by inserting one or more drop balls into a drilling fluid flow stream; pumping the drop balls in the drilling fluid down the drill string and into the bottom hole assembly; flowing the drilling fluid and drop balls through the NBR at a first hydraulic pressure; plugging one or more flow orifices (e.g., drill bit nozzles inlets or filter holes) thereby restricting flow of the drilling fluid upstream of the restriction and increasing the hydraulic pressure in the drilling fluid in the NBR upstream of the restriction to a predefined second hydraulic pressure. The increased hydraulic pressure acting on a surface of the NBR creates a shearing force on a shear pin which shears when it reaches a predetermined sheer force and allows the NBR to be activated with the predefined second hydraulic pressure of the drilling fluid flowing through the NBR.
[0029] FIGS. 3A-3C are cross-sectional perspective, top, and side views of a drill bit 22 fitted with a grate actuation assembly 300 designed to facilitate a drop-ball technique for increasing hydraulic pressure to activate the NBR 100 . In this example, the drill bit 22 is a fixed cutter directional drill bit with multiple (in this case, seven) nozzle inlets 302 for ejecting drilling fluid. However, the NBR-activation techniques discussed in the present disclosure are applicable to other suitable drill bits as well. As shown, the grate actuation assembly 300 is located in a central fluid passage 304 defined by the shank 306 of the drill bit 22 . The grate actuation assembly 300 abuts the base of the central fluid passage 304 to cover the nozzle inlets 302 .
[0030] The grate actuation assembly 300 includes a generally cylindrical body 308 having a sloped top surface 310 including a series of guide slots 312 . The sloped surface 310 and the guide slots 312 are designed to direct one or more drop balls (not shown) towards an opening 314 proximal to the wall of the central fluid passage 304 . As shown, the opening 314 provides access to the nozzle inlets 302 of the drill bit 22 . The guide slots 312 are formed having a width less than the diameter of the drop balls. This configuration allows the drilling fluid to pass through the guide slots 312 to reach the nozzle inlets 302 , while preventing the drop balls from passing through. A directional surface 316 leads the drop balls through the opening 314 and towards the nozzle inlets 302 . Thus, in this example, the directional surface 316 slopes in a direction opposing the sloped top surface 310 . Other suitable configurations and arrangements for leading the drop balls towards the drill bit nozzle inlets are also contemplated.
[0031] When the one or more drop balls encounter the nozzle inlets 302 , the nozzle inlets become plugged—preventing the ejection of drilling fluid. Thus, plugging the nozzle inlets 302 restricts the flow of the drilling fluid through the bottom hole assembly 10 . The flow restriction causes a hydraulic pressure increase in the drilling fluid up stream of the restriction. In this example, the grate actuation assembly 300 further includes a gate structure 318 partitioning the area of the central fluid passage 304 near the nozzle inlets 302 , creating a protected area 320 . The gate structure 318 prevents the drop balls from entering the protected area 320 and encountering the nozzle inlets 302 within. In summary, the grate actuation assembly 300 is designed to facilitate plugging at least some of the nozzles 302 in a first unprotected area of the bit but not the nozzle inlets 302 in the second protected area 320 . The increased hydraulic pressure acting on the assembly creates a shearing force on a shear pin which shears when it reaches a predetermined shear force and allows the NBR to be activated with the predefined second hydraulic pressure of the drilling fluid flowing through the NBR.
[0032] This configuration allows the hydraulic pressure within the bottom hole assembly 10 to be increased by a sufficient amount to activate the NBR 100 without entirely preventing the ejection of drilling fluid from the bit. The magnitude of hydraulic pressure increase scales with the number of nozzle inlets 302 that are plugged by drop balls. Thus, the grate actuation assembly 300 can be designed to allow access by the one or more drop balls to a specific number of nozzle inlets 302 , via positioning of the gate structure 318 , in order to achieve a specific hydraulic pressure increase.
[0033] FIGS. 4A-4C are sequential diagrams of a technique for using deformable drop balls 400 to activate the NBR 100 . The deformable drop balls are formed from a flexible material (e.g., a material including rubber, foam, and/or plastic). In this example, one or more deformable drop balls 400 are pumped through the bottom hole assembly 10 toward the nozzle inlets of the drill bit 22 . The deformable drop balls 400 encounter and plug the nozzle inlets to increase the hydraulic pressure within the bottom hole assembly 10 to a level sufficient to activate the NBR 100 . As the hydraulic pressure continues to increase within the bottom hole assembly 10 , the deformable drop balls 400 are eventually forced through the nozzle openings. For example, the deformable drop balls 400 can be designed to shred under hydraulic pressure and pass through the nozzle openings in smaller pieces. As another example, the deformable drop balls 400 can be designed to deform and compress (“squeeze”) through the nozzle openings under hydraulic pressure. In summary, the deformable drop balls 400 are designed to pass through the nozzle openings of the drill bit at a drilling fluid hydraulic pressure greater than what is required to activate the NBR 100 .
[0034] Controlling the hydraulic pressure increase within the bottom hole assembly 10 can be achieved by altering various process parameters (e.g., the number of deformable drop balls, the size of the deformable drop balls, the material properties of the deformable drop balls, etc.). In one example, the deformable drop balls 400 are Halliburton's Foam Wiper Balls, which are made of natural rubber of open cell design. In this example, the deformable drop balls are used to plug the nozzle inlets of the drill bit, but other configurations and arrangements are also contemplated. For example, the deformable drop balls can be used to plug any orifice(s) downstream of the NBR 100 .
[0035] The above-described technique involving deformable drop balls is an exemplary technique for temporarily increasing hydraulic pressure in the bottom hole assembly for activation of the NBR. However, other suitable techniques for temporarily increasing the bottom-hole-assembly hydraulic pressure are also contemplated. For example, FIG. 5 is a flowchart illustrating a method 500 that involves temporarily creating an upstream flow restriction to generate a positive hydraulic pressure pulse sufficient to activate the NBR 100 . At step 502 , a flow restriction is created upstream of the NBR 100 . The flow restriction can be created, for example, using an activation technique for operating a different downhole assembly tool. In one implementation, the conventional under reaming tool 14 is activated using a drop-ball technique that creates the temporary upstream flow restriction. In some other examples, an electronically activated valve is at least partially closed to create the temporary upstream flow restriction. At step 504 , the hydraulic pressure pulse activates the NBR 100 . At step 506 , the upstream flow restriction is relieved to reestablish the flow of drilling fluid.
[0036] FIG. 6 is a flowchart illustrating yet another method 600 for creating a temporary pressuring increase sufficient to activate the NBR 100 . The method 600 involves a highly viscous pill fluid. At step 602 , a general-purpose drilling fluid is pumped through the bottom hole assembly 10 . At step 604 , a high-viscosity pill fluid is pumped through the bottom hole assembly 10 in place of the general-purpose drilling fluid. Pumping the high-viscosity pill fluid creates a hydraulic pressure increase within the bottom hole assembly 10 that is sufficient to activate the NBR 100 . At step 606 , the pumping of the high-viscous pill fluid is ceased and the general-purpose drilling fluid is reestablished in the bottom hole assembly 10 , restoring the original hydraulic pressure. In some examples, the pill fluid is a high-viscosity liquid (e.g., mud gunk, such as Halliburton's Geltone), such as used for well cleaning operations. In some examples, the pill fluid is a slurry-type fluid including liquid and small solid additives (e.g., Halliburton's fine Lubra-Beads or lost circulation material).
[0037] In some implementations, a filter actuation assembly positioned upstream of the drill-bit nozzles and downstream of the NBR is used in conjunction with drop balls to generate a sufficient hydraulic pressure increase for activating the NBR 100 . The filter actuation assembly can include a filter head supported by one or more shear pins. The filter head includes an array of flow orifices designed with a small diameter for plugging by the drop balls. Plugging the flow orifices on the filter head creates a flow restriction that causes a hydraulic pressure increase. When then hydraulic pressure reaches a certain level (which is greater than the NBR-activation hydraulic pressure), the pressure force bearing on the filter head causes the shear pins to break. Without the supporting shear pins, the filter head moves to a new position in the bottom hole assembly and opens a new flow path for the drilling fluid to pass, which relieves the hydraulic pressure buildup.
[0038] FIG. 7 is a cross-sectional perspective view of a first example filter actuation assembly 700 . The filter actuation assembly 700 includes a filter head 702 , a set of axially oriented pillars 704 and a base plate 706 . The filter head 702 is mounted on one or more secondary radial shear pins (see FIGS. 7A-7B ). As shown, the filter head 702 defines an array of axial flow passages 708 aligned with the patterned flow openings 710 of the base plate 706 . The diameter of the axial flow passages 708 is smaller than the diameter of the drop balls, so that drop balls encountering the filter head 702 effectively plug the flow passages.
[0039] When the filter actuation assembly is free of any drop balls, the axial flow passages 708 and flow openings 710 allow drilling fluid to pass through the filter actuation assembly 700 . With the flow passages 708 being plugged by drop balls 712 , as shown in FIG. 7A , the flow of drilling fluid is restricted to the ancillary flow passages 714 at the radial edge of the filter head 702 and base plate 706 (see FIG. 7 ). The hydraulic pressure buildup eventually causes the shear pin 716 to break, allowing the filter head 702 to slide downward to rest against the base plate 706 . As the filter head 702 translates toward the base plate 706 , the pillars 704 project through the axial flow passages 708 to displace the drop balls 712 (See FIG. 7B ).
[0040] FIG. 8A is an exploded diagram illustrating a second example filter actuation assembly 800 . FIGS. 8B and 8C are perspective and cross-sectional side views of the filter actuation assembly 800 in an assembled form. As shown, the filter actuation assembly 800 includes a disc-shaped filter head 802 defining an array of axial flow passages 804 . The filter head 802 is supported in a hollow cylindrical rack 806 . The rack 806 includes an annular seat 808 for receiving the filter head 802 , three axially extending legs 810 that support the seat, and an annular base 812 .
[0041] A cylindrical sleeve 814 fits concentrically around the rack 806 . The sleeve 814 includes an inner sheath 816 and an outer sheath 818 . The inner sheath 816 defines an annular lip 820 that seals against the filter head 802 to prevent drilling fluid from leaking between the two filter-assembly components. The cylindrical side wall of the inner sheath 816 defines a plurality of axial slots 822 . As shown in FIGS. 8B and 8C , the sleeve 814 is held in place against the rack 806 by secondary shear pins 824 traversing radial openings 826 in the legs 810 of the rack and radial openings 828 in the outer sheath 818 .
[0042] FIGS. 8D-8F are sequential diagrams illustrating operation of the filter actuation assembly 800 . As shown in FIG. 8D , when the flow passages 804 (see FIGS. 8A to 8C ) of the filter head 802 are clear of any drop balls, drilling fluid flows downstream unimpeded through the filter head and the rack 806 . In FIG. 8E , when the drop balls 830 encounter the filter head 802 , the flow passages 804 (see FIGS. 8A to 8C ) become plugged, restricting the flow of drilling fluid through the bottom hole assembly 10 to build sufficient hydraulic pressure for activation of the NBR 100 . As the hydraulic pressure continues to build, the pressure acting on the filter head 802 and rack 806 create as force until the shear pins 824 are severed upon reaching a predetermined shear force. In FIG. 8F , when the shear pins 824 break, the filter head 802 and rack 806 slide downward relative to the stationary sleeve 814 . When the filter head 802 and rack 806 are in the lowered position, the axial slots 822 in the side wall of the inner sheath 816 are exposed, which provides a new flow path for the drilling fluid to pass through the bottom hole assembly 10 .
[0043] FIG. 9 is a cross-sectional perspective view of a third example filter actuation assembly 900 . In this example, the filter actuation assembly 900 includes a support member 902 mounted to the an interior wall of the bottom hole assembly 10 , a filter head 904 coupled to the support member, and an axial flow orifice 906 . The filter head 904 includes an array of radial flow openings 908 distributed along a frustoconical sidewall 910 . Before introduction of the drop balls, drilling fluid flows freely through the filter head 904 , passing through the radial flow openings 908 and the axial flow orifice 906 . When the drop balls encounter and plug the radial flow openings 908 , flow through the filter head 904 is severely inhibited, if not entirely prevented. Thus, the drilling fluid flow is restricted to an ancillary flow path formed by a gap 912 between the filter head 904 and the support member 902 . The restriction of fluid flow achieved by plugging the filter head 904 creates a hydraulic pressure increase sufficient to activate the NBR 100 .
[0044] FIG. 10A is a cross-sectional side view of a lower section of the bottom hole assembly 10 featuring an activation bushing 1000 . FIG. 10B is a cross-sectional perspective view of the activation bushing 1000 . In this example, the activation bushing is installed at the interface between the shank 1002 of the drill bit 22 and the central bore of the NBR 100 . However, it is appreciated that the activation busing 1000 could be located at any position within the bottom hole assembly 10 downstream of the NBR 100 . The activation bushing 1000 includes a flanged cylindrical base 1004 mounted and sealed against the wall of the central fluid passage 1006 in the drill bit 22 . A slotted inlet structure 1008 aligns with a main flow passage 1010 extending through the base 1004 of the activation bushing 1000 . Multiple ancillary flow passages 1012 are spaced circumferentially around the cylindrical base 1004 . As shown, the slotted inlet structure 1008 is provided with a sloped, conical tip that prevents drop balls from plugging the main flow passage 1010 . The ancillary flow passages 1012 on the other hand are oriented axially and designed to be plugged by the drop balls.
[0045] FIGS. 10C and 10D are sequential diagrams illustrating operation of the activation bushing 1000 . As shown in FIG. 10C , when the ancillary flow passages 1012 are clear of any drop balls, drilling fluid flows unimpeded through the ancillary flow passages and the main flow passage 1010 . In FIG. 10D , when the ancillary flow passages 1012 have been plugged by the drop balls 1014 , the flow of drilling fluid is confined to the main flow passage 1010 . The reduction in flow area achieved by plugging at least some of the ancillary flow passages 1012 creates a hydraulic pressure increase in the drilling fluid sufficient to activate the NBR 100 .
[0046] The use of terminology such as “above,” and “below” throughout the specification and claims is for describing the relative positions of various components of the system and other elements described herein. Similarly, the use of any horizontal or vertical terms to describe elements is for describing relative orientations of the various components of the system and other elements described herein. Unless otherwise stated explicitly, the use of such terminology does not imply a particular position or orientation of the system or any other components relative to the direction of the Earth gravitational force, or the Earth ground surface, or other particular position or orientation that the system other elements may be placed in during operation, manufacturing, and transportation.
[0047] A number of embodiments of the invention have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the invention. | A method of hydraulically activating a mechanically operated wellbore tool in a bottom hole assembly includes: holding moveable elements of the wellbore tool in an unactivated position using a shear pin; inserting one or more drop balls into a drilling fluid; and flowing the drilling fluid with the drop balls to a flow orifice located in or below the wellbore tool. The flow orifice is at least partially plugged with the drop balls to restrict fluid flow and correspondingly increases the hydraulic pressure of the drilling fluid. The hydraulic pressure is increased to a point beyond the rating of the shear pin, thereby causing the shear pin to shear and allowing the moveable elements of the tool to move to an activated position. | 4 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a document management system, a document processing device, a document processing control method thereof, and a program for executing the document processing control method. More particularly, the present invention relates to the document management system and the document processing device which execute a document process by using document process history information, and the document processing control method thereof.
[0003] 2. Related Background Art
[0004] In recent years, as document data have been digitized widely, a document management system which consists of a document management server for managing the document data, and various client devices such as a PC (personal computer), a printer and the like has come to be used. Thus, a user can access the document management server from the client device such as the PC, the printer or the like, and, by using the client device, execute document processes such as document registration, document acquirement, document update, document print and the like with respect to the document management server.
[0005] On the other hand, as the conventional art, the printer which comprises the storage unit for storing, every time a print job is executed, history information of the print job and PDL (page-description language) data corresponding to the relevant history information is disclosed (for example, Japanese Patent Application Laid-Open No. 2003-330638). In this printer, if a user indicates the print job by selecting one of the history information stored in the storage unit, the PDL data corresponding to the selected history information is read, whereby the read PDL data can be reprinted.
[0006] Therefore, if the relevant printer is applied to the client device in the document management system, it is thought that a trouble that a user specifies desired data from among a huge amount of document data managed by the document management server and then designates the specified desired data as print data can be reduced.
[0007] However, the relevant printer comprising the storage unit for storing the history information is merely to simplify the reprint process to be executed in response to the operation by an individual user. In other words, the relevant printer is merely corresponding to a local environment. For this reason, even where the relevant printer is directly applied to the client device, when one user (called a user 1 ) executes the print process with respect to the document data that the user 1 wishes to conceal from another user (called a user 2 ), there is a problem that the user 2 can acquire the printed matter corresponding to the relevant document data on the basis of the history information and thus the contents of the relevant document data leak.
[0008] The above problem can be solved by enabling only the user 1 who indicated the print process to actually execute the print process based on the history information. However, even in that case, there is a problem that, if the user 1 executes the print process for, e.g., shared document data, the user 2 cannot reprint the relevant shared document data based on the history information.
[0009] Further, since the above conventional art discloses the method by which the document data subjected to the print process in the past is used for the reprint process, even where a document process other than the print process was executed in the past, the document data concerning the relevant document process cannot be used for the reprint process.
SUMMARY OF THE INVENTION
[0010] An object of the present invention is to provide a document processing device which can, in a case where a user wishes to execute, by designating desired document data, a document process based on the designated document data, reduce a trouble of specifying the desired document data from among a huge amount of document data and conceal the data to which the user does not have an access right, a document processing method which is applicable to the document management system and the document processing device, and a program which is used to execute the document processing method.
[0011] To achieve the above object, according to one aspect of the present invention, there is provided a document processing device comprises, an authentication unit adapted to authenticate the user, a history information storage unit adapted to store history information indicating that document data was processed after the document data was stored in a document management server, the history information including identification information for identifying the document data was processed after the document data was stored in a document management server, a user access right judgment unit adapted to judge whether or not the authenticated user has an access right to each document data corresponding to the identification information included in the history information, a display unit adapted to display information for enable a user to select the document data to which the authenticated user has the access right from among the document data corresponding to the identification information included in the history information, and a processing unit adapted to process to the document data selected by the user.
[0012] Other features, objects and advantages of the present invention will be apparent from the following description when taken in conjunction with the accompanying drawings, in which like reference characters designate the same or similar parts throughout the figures thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate the embodiment of the present invention and, together with the description, serve to explain the principles of the present invention.
[0014] FIG. 1 is a block diagram schematically showing the constitution of the document management system according to the embodiment of the present invention;
[0015] FIGS. 2A, 2B and 2 C are diagrams showing the information to be managed in the DB (database) unit of the document management server, and, more specifically, FIG. 2A shows the document information, FIG. 2B shows the access right information, and FIG. 2 C shows the user information;
[0016] FIG. 3 is a diagram for explaining a history information storage process executed by the document management system shown in FIG. 1 ;
[0017] FIG. 4 is a diagram for explaining a reprint process executed by the document management system shown in FIG. 1 ;
[0018] FIG. 5 is a diagram showing the login screen to be displayed on the information display unit shown in FIG. 1 ;
[0019] FIG. 6 is a flow chart showing the procedure of a document list generation process executed by the print device shown in FIG. 1 ;
[0020] FIG. 7 is a flow chart showing the procedure of an access right information transmission process in the step S 603 shown in FIG. 6 ;
[0021] FIG. 8 is the diagram showing, in a case where the print operation is selected by a user, the display screen to be displayed after the “DESIGNATE FROM LIST” button is depressed on the document operation screen of the information display unit shown in FIG. 1 ;
[0022] FIGS. 9A and 9B are diagrams for explaining history information managed by the history management unit shown in FIG. 1 , and, more specifically, FIG. 9A shows the history information before update, and FIG. 9B shows the history information after update;
[0023] FIG. 10 is a diagram showing, in the case where the print operation is selected by the user, the display screen to be displayed after the “DESIGNATE FROM RECENTLY USED DOCUMENTS” button is depressed on the document operation screen of the information display unit shown in FIG. 1 ;
[0024] FIG. 11 is a diagram for explaining a modification of the history information storage process to be executed by the document management system shown in FIG. 1 ;
[0025] FIG. 12 is a diagram showing, in the case where the scan operation is selected by the user, the display screen to be displayed after the “DESIGNATE FROM LIST” button is depressed on the document operation screen of the information display unit shown in FIG. 1 ; and
[0026] FIG. 13 is a diagram showing a modification of the history information shown in FIG. 9 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0027] Hereinafter, the preferable embodiment of the present invention will be explained in detail with reference to the accompanying drawings.
[0028] FIG. 1 is a block diagram schematically showing the constitution of the document management system according to the embodiment of the present invention.
[0029] In FIG. 1 , a document management system 1 consists of a print device 110 , a PC 140 and a document management server 120 . Here, the print device 110 acts as the client device which is operated by a user to execute a communication process for exchanging data through a network 130 . Further, a general network such as a LAN (local area network), the Internet or the like is used as the network 130 . Also, a physical cable such as a USB (Universal Serial Bus) or the like may be used as the network 130 .
[0030] The print device 110 consists of a scan execution unit 116 for reading an original, a print execution unit (document processing means) 115 for executing a print process, an information display unit (display means) 114 for showing information to the user and also accepting requests from the user, an information processing unit 113 for generating the information to be shown to the user by the information display unit 114 and also analyzing the request accepted from the user, a communication unit 112 for executing communication with the document management server 120 through the network 130 , and a history information management unit (history information storage means) 111 for managing the history information of the operations executed in the print device 110 .
[0031] The document management server 120 consists of a communication unit 124 for executing a communication process with the print device 110 through the network 130 , a processing unit 125 for receiving an access right request and a document acquirement request later explained with reference to FIG. 4 from the print device 110 , analyzing the contents of these requests and executing the process according to the analyzed request in the document management server 120 , a DB unit 126 for storing document information 121 , access right information 122 and user information 123 later explained with reference to FIGS. 2A to 2 C, and a conversion unit 127 for converting the managed document data into the data capable of being printed by the print device 110 .
[0032] Incidentally, it is explained in FIG. 1 that the document management server 120 and the print device 110 are independent from each other. However, the document management server 120 and the print device 110 may be provided integrally. In such a case, one document processing device will consist of the history information management unit 111 , the information processing unit 113 , the information display unit 114 , the print execution unit 115 , the scan execution unit 116 , the processing unit 125 , the conversion unit 127 and the DB unit 126 .
[0033] FIGS. 2A, 2B and 2 C are diagrams showing the information to be managed in the DB unit 126 of the document management server 120 shown in FIG. 1 .
[0034] As shown in FIGS. 2A to 2 C, the DB unit 126 stores the document information 121 , the access right information 122 and the user information 123 .
[0035] The document information 121 is the information concerning the document data to be managed by the document management server 120 . More specifically, the document information 121 is the information for managing the document ID information representing a unique value with respect to a document, the document name representing the name of the document data, and the storage location information representing the location where the document data is stored, in the mutually associated state. Incidentally, although only the document ID information, the document name and the storage location information are shown by way of example in the present embodiment, but the present invention is not limited to them. That is, another information concerning the document may be managed in association with the document ID information, the document name and the storage location information.
[0036] The access right information 122 is the information representing presence/absence of the user's access right for the document data managed by the document management server 120 . More specifically, the access right information 122 is the information for managing the user ID information, the document ID information and the access right information “Read (reading)/Write (generating and changing)/Delete (deleting)/Nothing (no access right)” in the mutually associated state.
[0037] The user information 123 is the information representing the user who can use the document management system 1 . More specifically, the user information 123 is the information for managing the user ID information representing a unique value with respect to the user, the user name information representing a name of the user, and the login ID information representing a login ID of the user, and the password information representing a password of the user, in the mutually associated state.
[0038] Hereinafter, a case where, after a user A printed a document 1 and a document 2 by the print device 110 , a user B prints the document 1 by using the history information of the print operation by the user A will be explained with reference to FIGS. 3 and 4 .
[0039] FIG. 3 is the diagram for explaining a history information storage process which is executed by the document management system 1 .
[0040] In FIG. 3 , the print device 110 first displays the document processing menu on the information display unit 114 . Then, in a case where the user A selects the print process from the displayed document processing menu, the print device 110 displays a login screen 500 ( FIG. 5 ) on the information display unit 114 to request the user A to input the login ID and the password.
[0041] If the login ID and the password are input by the user A, the print device 110 transmits a login request consisting of the input login ID and the input password to the document management server 120 through the communication unit 112 .
[0042] Then, if the login request from the print device 110 is received through the communication unit 124 , the document management server 120 causes the processing unit 125 to check the user information managed in the user information 123 with the login ID and the password both included in the received login request. If the check by the document management server 120 succeeds, then the document management server 120 notifies the print device 110 through the communication unit 124 that the user A has been logged in.
[0043] Subsequently, if the notification that the user A has been logged in is received from the document management server 120 , the print device 110 displays a document operation screen 800 shown in FIG. 8 . After then, if the request (server document request) to designate the print document from the document data of the document information 121 managed by the document management server 120 is issued from the user A on the document operation screen 800 (step S 301 ), the print device 110 requests the document management server 120 to transmit the list including the server documents (step S 302 ). More specifically, if a “DESIGNATE FROM LIST” button 801 shown in FIG. 8 is selected by the user, the print device 110 detects that the document designation from the list is requested.
[0044] If the server document list request is received, the document management server 120 generates the data representing the list of the document data capable of being accessed by the logged-in user A, by using the access right information 122 and the document information 121 . Then, the document management server 120 transmits the generated data to the print device 110 as a server document list.
[0045] If the print device 110 acquires the server document list form the document management server 120 (step S 303 ), the acquired server document list is converted into the data (that is, a folder tree 802 and a list screen 803 ) capable of being displayed by the information display unit 114 , and the document in the converted data is shown by using the information display unit 114 so as to be selectable by the user (step S 304 ). Then, if the documents (that is, the document 1 and the document 2 in the present embodiment) are designated in the shown list by the user A (step S 305 ), the print device 110 requests the document management server 120 to acquire the document 1 and the document 2 through the communication unit 112 (step S 306 ). More specifically, if a “DECIDE” button 804 shown in FIG. 8 is selected by the user, the print device 110 detects that the document acquisition request is issued.
[0046] If the document acquisition request is received from the print device 110 , the document management server 120 acquires the document 1 and the document 2 in the document information 121 . Then, the acquired information is converted by the conversion unit 127 into the data capable of being printed, and the converted data is then transmitted to the print device 110 .
[0047] If the data representing the documents 1 and 2 capable of being printed is acquires from the document management server 120 (step S 307 ), the print device 110 displays the print format setting screen. Then, the received data is printed by the print execution unit 115 in the document print format selected by the user based on the displayed contents (step S 308 ). If the print ends, as shown in FIG. 9A , the print device 110 registers the information concerning the printed document data and the date and time when the print was executed (that is, the document ID information and the operation date and time information managed by the document management server 120 ) to the history information management unit 111 as the history information (step S 309 ).
[0048] In the explanation of FIG. 3 , the print device 110 prints the document data selected by the user A. However, the present invention is not limited to this. That is, it is possible to attach the document data selected by the user A to an electronic mail and then transmit the relevant electronic mail to a predetermined electronic mail address, and it is also possible to transmit the document data selected by the user A through facsimile.
[0049] FIG. 4 is the diagram for explaining a reprint process which is executed by the document management system 1 .
[0050] In FIG. 4 , in the first instance, the print device 110 executes the process same as the login process for the user A shown in FIG. 3 , whereby a user B is logged in. Thus, the document operation screen 800 as shown in FIG. 10 is displayed on the information display unit 114 . Then, when a request (history information request) to designate the print document from the list of the recently used documents is input by the user B on the document operation screen 800 through the print device 110 (YES in step S 401 ), the process advances to a step S 402 . Here, if a “DESIGNATE FROM RECENTLY USED DOCUMENTS” button 1002 shown in FIG. 8 is selected by the user, the print device 110 detects that the history information is requested. Incidentally, in the present embodiment, it is assumed that only the print operation histories of the documents 1 and 2 by the user A exist in the history information.
[0051] In the step S 402 , the print device 110 requests the access right information to the document management server 120 . Here, it should be noted that the access right information represents, from among the document data corresponding to the document ID included in the history information, to which document data the user B has the access right. After then, the access right information generated by the document management server 120 is acquired in response to such a request (step S 403 ), and the list of the documents to which the user B has the access right is generated based on the acquired access right information. Incidentally, the process from the step S 402 to the document list generation will be explained in detail with respect to a later-described document list generation process shown in FIG. 6 .
[0052] Next, the print device 110 causes the information display unit 114 to show the list (a list screen 1001 shown in FIG. 10 ) of the documents capable of being reprinted, based on the generated history information (step S 404 ). Here, it should be noted that the documents on the list screen 1001 are displayed so as to be selectable by the user, and only the document 1 is displayed on the list screen 1001 in the present embodiment.
[0053] If one of the documents included in the shown list (that is, the document 1 in the present embodiment) is designated by the user B (step S 405 ), the print device 110 requests, through the communication unit 112 , the document management server 120 to acquire the document 1 by using the document ID (step S 406 ). More specifically, if the “DECIDE” button 804 shown in FIG. 10 is selected by the user, the print device 110 detects that the document acquisition request is issued.
[0054] If the document acquisition request from the print device 110 is received by the document management server 120 , the document data of the document 1 in the document information 121 is acquired by the processing unit 125 . Then, the acquired information is converted by the conversion unit 127 into the data capable of being printed, and the converted data is then transmitted to the print device 110 .
[0055] If the data representing the document 1 capable of being printed is acquires from the document management server 120 (step S 407 ), the print device 110 displays the print format setting screen. Then, the received data is printed by the print execution unit 115 in the document print format selected by the user based on the displayed contents (step S 408 ).
[0056] According to the processes shown in FIGS. 3 and 4 , in the case where the history information is requested from the user B (step S 401 ) after the history information was registered in the processes as shown in FIG. 3 , the print device 110 acquires the access right information from the document management server 120 (steps S 402 and S 403 ). Then, the list of the document data, to which the user B has the access right, from among the document data (document 1 and document 2 ) corresponding to the identification information included in the history information is generated based on the acquired access right information, and the generated list is shown to the user (step S 404 ). Subsequently, when the user B designates the document 1 from the shown list (step S 405 ), the print data of the document 1 is acquired from the document management server 120 (steps S 406 and S 407 ), and the acquired print data is actually printed (step S 408 ). Thus, even if the document management server 120 has to manage a huge amount of document data when the user B executes the print process by using the print device 110 , it is possible to reduce a trouble of designating as the print data one document data from among the huge amount of document data.
[0057] Further, the print device 110 does not display on the list screen 1001 the document 2 to which the user B does not have the access right. Thus, it is possible to conceal, from among the document data to be managed by the document management server 120 , the document data (the document 2 ) to which the user B does not have the access right. As a result, since it is possible to inhibit the user B from indicating the print of the document 2 , it is possible to increase security and it is also possible to prevent occurrence of operation errors.
[0058] Moreover, if the print ends in the step S 408 , as shown in FIG. 9B , the operation date and time information of the print operation history information for the document 1 managed by the history information management unit 111 is updated from the information representing the date and time when the print process is executed by the user A to the information representing the date and time when the reprint process is executed by the user B. After the information was updated, the list of the documents capable of being subjected to the reprint process based on the history information is updated. Thus, the user can always execute the print process based on the latest history information.
[0059] Furthermore, when the list is shown to the user B in the step S 404 , it is possible to simultaneously display the name of the document data to which the document process was executed in the past, the storage destination of the relevant document data in the document management server 120 , and the date and time information representing the date and time when the relevant document process was executed. Thus, it is possible to grasp or comprehend all at once the contents of the document data that the authenticated user can designate as the print data.
[0060] Moreover, in the present embodiment, since the access right settings that the plural client devices including the print device 110 request to change are updated in a lump by the document management server 120 , it is possible to instantly reflect such update in the print process based on the history information, whereby it is possible to easily mange the whole system.
[0061] In the explanation of FIG. 4 , the document data selected by the user B is printed by the print device 110 . However, the present invention is not limited to this. That is, it is possible to attach the document data selected by the user B to an electronic mail and then transmit the relevant electronic mail to a predetermined electronic mail address, and it is also possible to transmit the document data selected by the user through facsimile.
[0062] FIG. 6 is a flow chart showing the procedure of the document list generation process to be executed by the print device 110 shown in FIG. 1 .
[0063] In FIG. 6 , it is first judged whether or not the history information exists in the history information management unit 111 (step S 601 ). Then, if it is judged that the history information exists in the history information management unit 111 , it requests, to the document management server 120 through the communication unit 112 , the acquisition of the access right information of the user B for the history information of all the documents executed in the past with respect to the document management server 120 (step S 602 ). At that time, all the document ID's and the user ID of the user B stored as the history information are simultaneously transmitted to the document management server 120 .
[0064] If the request of the acquisition of the access right information is received through the communication unit 124 , the document management server 120 executes a later-described access right information transmission process shown in FIG. 7 to transmit the access right information including the document ID of the document to which the user B has the access right to the print device 110 (step S 603 ).
[0065] If the access right information is received from the document management server 120 , it is judged by the print device 110 whether or not the check of presence/absence of the access right of the user B to the history information of all the document executed for the document management server 120 in the past ends (step S 604 ). More specifically, if the comparison of the access right information received from the document management server 120 with all the document ID's of the documents included in the history information ends, it is judged that the check ends.
[0066] If it is judged in the step S 604 that the check does not end, it is further judged whether or not the user B has the access right to the document to which the check does not end (step S 605 ). More specifically, if the document ID of the document to which the check is currently executed is included in the access right information received from the document management server 120 , it is judged that the user B has the access right to the relevant document. Meanwhile, if the document ID is not included in the access right information, it is judged that the user B does not have the access right to the relevant document.
[0067] Then, after the step S 605 , the document name and the storage location information are directly added to the document to which the user B does not have the access right, or the document name and the storage location information are added to the document list of the document to which the user B has the access right (step S 606 ). Subsequently, the processes in the step S 604 and the subsequent steps are repeated.
[0068] If it is judged in the step S 604 that the check ends, the document list is sorted with the designated item (step S 607 ), and the document list generation process ends.
[0069] FIG. 7 is a flow chart showing the procedure of the access right information transmission process in the step S 603 shown in FIG. 6 .
[0070] Here, it should be noted that the access right information transmission process is executed by the document management server 120 .
[0071] In FIG. 7 , if the request of the step S 602 to acquire the access right information of the user B is received from the print device 110 by the processing unit 125 (YES in a step S 701 ), it is then judged whether or not the check of presence/absence of the access right of the user B to all the documents ends (step S 702 ). More specifically, if the comparison of the access right information 122 with all the documents of the document ID transmitted from the print device 110 when the request of the step S 602 is issued ends, it is judged that the check ends. In the present embodiment, since the history information includes only the histories of the print operations of the document 1 and the document 2 , it is judged in the step S 702 whether or not the check of presence/absence of the access right to the document 1 and the document 2 ends.
[0072] If it is judged in the step S 702 that the check does not end, the information representing whether or not the user B has the access right to the document to which the check does not end is acquired (step S 703 ), and the processes in the step S 702 and the subsequent steps are repeated. In the acquisition process, if the user ID of the user B is included in the user ID of the document in the access right information 122 , it is judged that the user B has the access right. Meanwhile, if the user ID of the user B is not included in the user ID of the document in the access right information 122 , it is judged that the user B does not have the access right.
[0073] Then, when the check ends in the step S 702 , the document ID and the storage destination information thereof are acquired with respect to the document to which the information to which the user B has the access right is acquired in the step S 703 , and the access right information including the acquired various information data is generated (step S 704 ). In the present embodiment, since it is set that the user B has the access right only to the document 1 , the document management server 120 generates the access right information including the document ID of the document 1 and the storage destination information thereof.
[0074] After then, the generated access right information is transmitted from the communication unit 124 to the print device 110 (step S 705 ), and the access right information transmission process ends.
[0075] According to the processes shown in FIGS. 6 and 7 , as well as the access right request, the print device 110 transmits the document ID and the user ID of the user A included in the history information to the document management server 120 (step S 602 ), and, through the access right information transmission process, the print device 110 receives the access right information including the document ID from the document management server 120 (step S 603 ). In this instance, it is judged that the user B has the access right to the document data of the relevant document ID (YES in step S 605 ). On the other hand, as well as the reception of the access right request from the print device 110 in the step S 602 , the document management server 120 receives the document ID (step S 701 ). Then, in the document management server 120 , the access right information including the document ID of the document data that the access right is set to the transmitted user ID based on the access right information 122 included in the received document ID is generated (step S 704 ), and the generated access right information is transmitted to the print device 110 (step S 705 ). Thus, it is possible on the side of the print device 110 to surely judge to which of the document data corresponding to the document ID included in the history information the user B has the access right. Further, if there is the document to which the user B has the access right from among the documents included in the history information (YES in step S 605 ), the document name of the relevant document and the information of the storage location of the relevant document are added to the document list of the documents capable of being reprinted (step S 606 ). Thus, it is possible to surely conceal from the user B the document data that the user A does not wish to make the user B to know the contents.
[0076] FIG. 8 is the diagram showing the document operation screen to be displayed in the step S 304 of FIG. 3 .
[0077] More specifically, the screen shown in FIG. 8 is the screen which is displayed in the step S 304 after the server document is requested by the user in the step S 301 by selecting the “DESIGNATE FROM LIST” button 801 on the document operation screen 800 with the user.
[0078] On the screen shown in FIG. 8 , if a folder 805 in which the desired document data have been held is selected by the user in a leftward folder tree 802 , the list of the document data held in the selected folder 805 is displayed on a center list screen 803 . Then, the user A selects the document corresponding to the desired data (document 1 and document 2 ) from the document data list displayed on the list screen 803 .
[0079] For example, if the folder which contains the data desired by the user A exists on the tenth layer (hierarchy), it is necessary to open the relevant layer by selecting the folders of the folder tree 802 ten times. Further, since the number of document data capable of being displayed on the list screen 803 at a time is limited, if a large number of document data are held in one folder, it is necessary to browse the document data in the relevant folder by scrolling them. Furthermore, if the user does not correctly know or grasp in which folder the desired data has been stored, the user A has to search various folders displayed in the folder tree 802 . In such a case, the user A has to open the layers by selecting ten or more folders.
[0080] FIG. 10 is a diagram showing the document operation screen which is displayed in the step S 404 of FIG. 4 .
[0081] More specifically, the screen shown in FIG. 10 is the screen to be displayed in the process of the step S 404 after the user requests the history information in the step S 401 of FIG. 4 by selecting the “DESIGNATE FROM RECENTLY USED DOCUMENTS” button 1002 on the document operation screen 800 .
[0082] On the center list screen 1001 shown in FIG. 10 , the document list generated based on the access right information and the history information is displayed.
[0083] Consequently, even if the user B does not operate or handle the folder tree 802 and the list screen 803 ( FIG. 8 ), the names of the desired documents are displayed on the list screen, the user B can easily execute the document selection.
[0084] Typically, the user interface of the device such as the print device 110 is smaller in size than that of the PC, whereby it is difficult for the user to operate or handle it. For this reason, if it is possible to decrease the user's operations even by one, it is possible to make the user interface significantly easy-usable for the user.
[0085] Next, a case where, after the user A scanned the documents 1 and 2 by the print device 110 , the user B prints the document 1 by using the history information of the scan operation will be explained with reference to FIG. 11 .
[0086] FIG. 11 is the diagram for explaining a modification of the history information storage process to be executed by the document management system 1 shown in FIG. 1 .
[0087] In FIG. 11 , the print device 110 first displays the document processing menu on the information display unit 114 . Then, if a user C scans new document data in the displayed document processing menu to request the process to be registered to the document management server 120 (scan registration request) (step S 1101 ), the process same as the login process to the user A shown in FIG. 3 is executed. Subsequently, if the user C is logged for the document management sever 120 , a document operation screen 1200 as shown in FIG. 12 is displayed on the information display unit 114 .
[0088] After then, the storage destination folder (“FIRST BUSINESS SECTION” folder) in a folder tree 1201 disposed at the left on the document operation screen 1200 is selected by the user, the document name (“DOCUMENT 1”) of the new document acquired by the scan is input by the user to a registration file name description section 1202 , and the “DECIDE” button is then depressed by the user. Thus, the print device 110 scans a paper original set on the scan execution unit 116 (step S 1102 ), converts the scanned data into the electronic data by the information processing unit 113 , and then transmits the scanned electronic data, the document name and the storage folder information from the communication unit 112 to the document management server 120 (step S 1103 ).
[0089] Subsequently, the document management server 120 registers the received electronic data to the document information 121 as the folder destination and the document name both designated by the user on the document operation screen 1200 . At this point, since the access right to the document 1 is given only to the user A, the information representing that the user A can access the document 1 is registered to the access right information 122 . Further, when the electronic data is registered to the document information 121 , the document ID information by which the registered document can be uniquely specified is generated and registered together. When the registration of document ends, the document management server 120 transmits the registration end notification, and the information representing the registered document name and the document ID issued at the time of registration to the print device 110 .
[0090] If the registration end notification is received from the document management server 120 , the print device 110 registers the registered document ID and the date and time when the registration was executed to the history information management unit 111 as the history of registration (step S 1104 ). In addition, it should be noted that the document 2 is registered in the manner same as above.
[0091] After the above registration process ended, the user C accesses the document management server 120 from the PC 140 to set the access right to the registered documents 1 and 2 (step S 1105 ).
[0092] After then, a user D can print the document 1 based on the history information of the scan registration process shown in FIG. 11 , by executing the process same as the reprint process in FIG. 4 executed by the user B.
[0093] FIG. 3 is the diagram for explaining the history information storage process which is executed by the document management system 1 .
[0094] According to the processes shown in FIG. 11 , after the history information is newly added and registered through the processes shown in FIG. 4 (step S 1104 ), and if the access right of the newly registered document is set by the PC 140 to the document management server 120 (step S 1105 ), then the print device 110 can execute the print process same as that shown in FIG. 4 on the basis of the operation or handling by the user D. Consequently, even if the scan registration process was executed in the print device 110 in the past, it is possible to execute the print process based on the history information thereof.
[0095] Likewise, after the shared document was registered from the print device 110 , if the access right to the shared document is set to all the users of the relevant system, it is possible for other users to easily execute the print by using the registered history information.
[0096] Incidentally, it should be noted that the print format setting information may be included in the information to be managed as the history information. In the history information storage process in this case, the print format information designated by the user in the step S 308 as shown in FIG. 13 is included as the information to be stored as the history information in the step S 309 of FIG. 3 . Further, in the reprint process to be executed thereafter, the print format setting screen is not displayed in the step S 408 of FIG. 4 , and the document data designated by the user in the step S 405 is printed with the print format of the print format information included in the history information with respect to the relevant document data.
[0097] Thus, since the print format of the document data which was set in the past print process is set as the print format when the reprint process of the relevant document data is executed based on the history information, it is unnecessary for the user to set the print format in the reprint process, whereby it is possible to more simplify the user's operation.
[0098] Further, for example, in a case where the user who is skilled in setting the print device 110 once executed the print with the complicated print setting, it is then possible for another user who is not skilled in setting the print format to easily execute the reprint with the relevant complicated print setting based on the history information.
[0099] Furthermore, it can be obviously understood that the object of the present invention can be attained even in a case where a storage medium (or a recording medium) storing therein the program codes of software to achieve the functions of the above embodiment is supplied to a system or a device, and thus the computer (or CPU, MPU) in the system or the device reads and executes the program codes stored in the medium.
[0100] In this case, the program codes themselves read out of the storage medium achieve the functions of the above embodiment, whereby the storage medium storing these program codes constitutes the present invention.
[0101] Further, it can be obviously understood that the present invention includes not only the case where the functions of the above embodiment are achieved by executing the program codes read by the computer, but also the case where an OS (operating system) or the like running on the computer executes a part or all of the actual processes based the instructions of the program codes and thus the functions of the above embodiment are achieved by these processes.
[0102] Furthermore, it can be obviously understood that the present invention also includes a case where, after the program codes read out of the storage medium are written into the memory of a function expansion card inserted in the computer or the memory in a function expansion unit connected to the computer, the CPU or the like provided in the function expansion board or the function expansion unit executes a part or all of the actual processes based on the instructions of the program codes, and thus the functions of the above embodiment are achieved by these processes.
[0103] Moreover, because the form of such a program is no object if it has the actual function as the program to be achieved by the computer, an object code, a program executed by an interpreter, script data supplied to the OS, and the like may be included as the program.
[0104] As the storage medium for supplying the program, for example, a RAM, an NV-RAM, a floppy™ disk, an optical disk, a magnetooptical disk, a CR-ROM, an MO, a CD-R, a CD-RW, a DVD (DVD-ROM, DVD-RAM, DVD-RW, DVD+RW), a magnetic tape, a nonvolatile memory card, another ROM, or the can be used, if the relevant medium can store the program. Alternatively, the relevant program is supplied by downloading it from a not-shown another computer, a database or the like connected to the Internet, a commercial network, a local area network or the like.
[0105] This application claims priority from Japanese Patent Application No. 2005-061333 filed Mar. 4, 2005, which is hereby incorporated by reference herein. | A document processing device comprises, an authentication unit adapted to authenticate the user, a history information storage unit adapted to store history information indicating that document data was processed after the document data was stored in a document management server, the history information including identification information for identifying the document data was processed after the document data was stored in a document management server, a user access right judgment unit adapted to judge whether or not the authenticated user has an access right to each document data corresponding to the identification information included in the history information, a display unit adapted to display information for enable a user to select the document data to which the authenticated user has the access right from among the document data corresponding to the identification information included in the history information, and a processing unit adapted to process to the document data selected by the user. | 6 |
RELATED REFERENCES
[0001] This application is a divisional of application Ser. No. 09/669,344, filed Sep. 26, 2000.
BACKGROUND OF THE INVENTION
[0002] The present invention relates in general to the field of proton exchange membrane (“PEM”) fuel cell systems, and more particularly, to an improved PEM fuel cell system having improved discrete fuel cell modules with improved mass transport for ternary reaction optimization and a method for manufacturing same.
[0003] A fuel cell is an electrochemical device that converts fuel and oxidant into electricity and a reaction by-product through an electrolytic reaction that strips hydrogen molecules of their electrons and protons. Ultimately, the stripped electrons are collected into some form of usable electric current, by resistance or by some other suitable means. The protons react with oxygen to form water as a reaction by-product.
[0004] Natural gas is the primary fuel used as the source of hydrogen for a fuel cell. If natural gas is used, however, it must be reformed prior to entering the fuel cell. Pure hydrogen may also be used if stored correctly. The products of the electrochemical exchange in the fuel cell are DC electricity, liquid water, and heat. The overall PEM fuel cell reaction produces electrical energy equal to the sum of the separate half-cell reactions occurring in the fuel cell, less its internal and parasitic losses. Parasitic losses are those losses of energy that are attributable to any energy required to facilitate the ternary reactions in the fuel cell.
[0005] Although fuel cells have been used in a few applications, engineering solutions to successfully adapt fuel cell technology for use in electric utility systems have been elusive. Fuel cells would be desirable in this application because they convert fuel directly to electricity at much higher efficiencies than internal combustion engines, thereby extracting more power from the same amount of fuel. This need has not been satisfied, however, because of the prohibitive expense associated with such fuel cell systems. For a fuel cell to be useful in utility applications, the life of the fuel cell stack must be a minimum of five years and operations must be reliable and maintenance-free. Heretofore known fuel cell assemblies have not shown sufficient reliability and have disadvantageous maintenance issues. Despite the expense, reliability, and maintenance problems associated with heretofore known fuel cell systems, because of their environmental friendliness and operating efficiency, there remains a clear and present need for economical and efficient fuel cell technology for use in residential and light-commercial applications.
[0006] Fuel cells are usually classified according to the type of electrolyte used in the cell. There are four primary classes of fuel cells: (1) proton exchange membrane (“PEM”) fuel cells, (2) phosphoric acid fuel cells, and (3) molten carbonate fuel cells. Another more recently developed type of fuel cell is a solid oxide fuel cell. PEM fuel cells, such as those in the present invention, are low temperature low pressure systems, and are, therefore, well-suited for residential and light-commercial applications. PEM fuel cells are also advantageous in these applications because there is no corrosive liquid in the fuel cell and, consequently, there are minimal corrosion problems.
[0007] Characteristically, a single PEM fuel cell consists of three major components—an anode gas dispersion field (“anode”); a membrane electrode assembly (“MEA”); and a cathode gas and liquid dispersion field (“cathode”). As shown in FIG. 1, the anode typically comprises an anode gas dispersion layer 502 and an anode gas flow field 504 ; the cathode typically comprises a cathode gas and liquid dispersion layer 506 and a cathode gas and liquid flow field 508 . In a single cell, the anode and the cathode are electrically coupled to provide a path for conducting electrons between the electrodes through an external load. MEA 500 facilitates the flow of electrons and protons produced in the anode, and substantially isolates the fuel stream on the anode side of the membrane from the oxidant stream on the cathode side of the membrane. The ultimate purpose of these base components, namely the anode, the cathode, and MEA 500 , is to maintain proper ternary phase distribution in the fuel cell. Ternary phase distribution as used herein refers to the three simultaneous reactants in the fuel cell, namely hydrogen gas, water vapor and air. Heretofore known PEM fuel cells, however, have not been able to efficiently maintain proper ternary phase distribution. Catalytic active layers 501 and 503 are located between the anode, the cathode and the electrolyte. The catalytic active layers 501 and 503 induce the desired electrochemical reactions in the fuel cell. Specifically, the catalytic active layer 501 , the anode catalytic active layer, rejects the electrons produced in the anode in the form of electric current. The oxidant from the air that moves through the cathode is reduced at the catalytic active layer 503 , referred to as the cathode catalytic active layer, so that it can oxidate the protons flowing from anode catalytic active layer 501 to form water as the reaction by-product. The protons produced by the anode are transported by the anode catalytic active layer 501 to the cathode through the electrolyte polymeric membrane.
[0008] The anode gas flow field and cathode gas and liquid flow field are typically comprised of pressed, polished carbon sheets machined with serpentine grooves or channels to provide a means of access for the fuel and oxidant streams to the anode and cathode catalytic active layers. The costs of manufacturing these plates and the associated materials costs are very expensive and have placed constraints on the use of fuel cells in residential and light-commercial applications. Further, the use of these planar serpentine arrangements to facilitate the flow of the fuel and oxidant through the anode and cathode has presented additional operational drawbacks in that they unduly limit mass transport through the electrodes, and therefore, limit the maximum power achievable by the fuel cell.
[0009] One of the most problematic drawbacks of the planar serpentine arrangement in the anode and cathode relates to efficiency. In conventional electrodes, the reactants move through the serpentine pattern of the electrodes and are activated at the respective catalytic layers located at the interface of the electrode and the electrolyte. The actual chemical reaction that occurs at the anode catalyst layer is: H 2 Ξ2H + +2e − . The chemical reaction at the cathode catalyst layer is: 2H + +2e − +½O 2 ΞH 2 O. The overall reaction is: H 2 +½O 2 ΞH 2 O. The anode disburses the anode gas onto the surface of the active catalyst layer comprised of a platinum catalyst electrolyte, and the cathode disburses the cathode gas onto the surface of the catalytic active layer of the electrolyte. However, when utilizing a conventional serpentine construction, the anode gas and the cathode gas are not uniformly disbursed onto the electrolyte. Nonuniform distribution of the anode and cathode gas at the membrane surface results in an imbalance in the water content of the electrolyte. This results in a significant decrease in efficiency in the fuel cell.
[0010] The second most problematic drawback associated with serpentine arrangements in the electrodes relates to the ternary reactions that take place in the fuel cell itself. Serpentine arrangements provide no pressure differential within the electrodes. This prohibits the necessary ternary reactions from taking place simultaneously. This is particularly problematic in the cathode as both a liquid and a gas are transported simultaneously through the electrode's serpentine pattern.
[0011] Another shortcoming of the conventional serpentine arrangement in the anode in particular is that the hydrogen molecules resist the inevitable flow changes in the serpentine channels, causing a build-up of molecular density in the turns in the serpentine pattern, resulting in temperature increases at the reversal points. These hot spots in the serpentine arrangement unduly and prematurely degrade the catalytic active layer and supporting membrane.
[0012] In the typical PEM fuel cell assembly, a PEM fuel cell is housed within a frame that supplies the necessary fuel and oxidant to the flow fields of the fuel cell. These conventional frames typically comprise manifolds and channels that facilitate the flow of the reactants. However, usually the channels are not an integral part of the manifolds, which results in a pressure differential along the successive channels. FIG. 2 is an illustration of a conventional frame for the communication of the reactants to a fuel cell. This pressure differential causes the reactants, especially the fuel, to be fed into the flow fields unevenly, which results in distortions in the flow fields causing hot spots. This also results in nonuniform disbursement of the reactants onto the catalytic active layers. Ultimately, this conventional method of supplying the necessary fuel and oxidant to a fuel cell results in a very inefficient process.
[0013] As a single PEM fuel cell only produces about 0.30 to 0.90 volts D.C. under a load, the key to developing useful PEM fuel cell technology is being able to scale-up current density in individual PEM cell assemblies to produce sufficient current for larger applications without sacrificing fuel cell efficiency. Commonly, fuel cell assemblies are electrically connected in nodes that are then electrically connected in series to form “fuel cell stacks” by stacking individual fuel cell nodes. Two or more nodes can be connected together, generally in series, but sometimes in parallel, to efficiently increase the overall power output.
[0014] Conventional PEM fuel stacks often flood the cathode due to excess water in the cathode gas flow field. Flooding occurs when water is not removed efficiently from the system. Flooding is particularly problematic because it impairs the ability of the reactants to adequately diffuse to the catalytic active layers. This significantly increases the internal resistance of the cathode which ultimately limits the cell voltage potential. Another problem is dehydration of the polymeric membranes when the water supply is inadequate. Insufficient supply of water can dry out the anode side of the PEM membrane electrolyte, causing a significant rise in stack resistance and reduced membrane durability.
[0015] Further, conventional PEM fuel cells and stacks of such fuel cell assemblies are compressed under a large load in order to ensure good electrical conductivity between cell components and to maintain the integrity of compression seals that keep various fluid streams separate. A fuel cell stack is usually held together with extreme compressive force, generally in excess of 40,000 psi, using compression assemblies, such as tie rods and end plates. If tie rods are used, the tie rods generally extend through holes formed in the peripheral edge portion of the stack end plates and have associated nuts or other fastening means assembling the tie rods to the stack assembly to urge the end plates of the fuel stack assembly toward each other. Typically, the tie rods are external, i.e., they do not extend through the fuel cell electrochemically active components. This amount of pressure that must be used to ensure good electrochemical interactions presents many operational difficulties. For example, if the voltage of a single fuel cell assembly in a stack declines significantly or fails, the entire stack must be taken out of service, disassembled, and repaired, resulting in significant repair costs and down-time. Second, inadequate compressive force can compromise the seals associated with the manifolds and flow fields in the central regions of the interior distribution plates, and also compromise the electrical contact required across the surfaces of the plates and MEAs to provide the serial electrical connection among the fuel cells that make up the stack. Third, the extreme compressive force used unduly abrades the surfaces of the fuel cell modules within the stack, resulting in wear of components in the fuel cell assemblies such as the catalyst layers of the electrolyte, thereby leading to increased losses in fuel cell stack and fuel cell assembly efficiency.
SUMMARY OF THE INVENTION
[0016] Herein provided is a fuel cell assembly and fuel cell stack assembly. One embodiment of a fuel cell of the present invention comprises (a) a distribution frame having: (i) an anode side, a cathode side and a central cavity suitable for housing a fuel cell assembly; (ii) at least 2 fuel inlet apertures, the fuel inlet apertures extending completely through the distribution frame and each fuel inlet aperture being located 180° from the other, and each fuel inlet aperture having an interior side; (iii) an air inlet aperture, the air inlet aperture extending completely through the distribution frame and the air inlet aperture being located 90° from each fuel inlet aperture and 180° from an air and water outlet aperture, the air and water outlet aperture extending completely through the distribution frame, the air inlet aperture and the air and water outlet aperture each further having an interior side; (iv) a plurality of fuel supply channels, the fuel supply channels located on the anode side of the distribution frame and extending from the interior side of each fuel inlet aperture to the central cavity and being integral to each fuel inlet aperture; a plurality of air supply channels, the air supply channels located on the cathode side of the distribution frame and the air supply channels extending from the interior side of the air inlet aperture to the central cavity and being integral to the air inlet aperture; and (vi) a plurality of air and water outlet channels, the air and water outlet channels located on the cathode side of the distribution frame, the air and water outlet channels extending from the interior side of the air and water outlet aperture to the central cavity, and being integral to the air and water outlet aperture; and (b) a fuel cell assembly having: (i) an MEA having two catalytic active layers, the MEA further having an anode side and a cathode side, the MEA having an electrolyte; (ii) a gas diffusion layer, the gas diffusion layer having a top face and a bottom face, the bottom face of the gas diffusion layer juxtaposed to the anode side of the electrolyte; (iii) a gas and liquid diffusion layer, the gas and liquid diffusion layer having a top face and a bottom face, the top face of the gas and liquid diffusion layer juxtaposed to the cathode side of the electrolyte; (iv) an anode gas flow field comprising a three-dimensional open-cell foamed structure suitable for gas diffusion, the anode gas flow field juxtaposed to the top face of the gas diffusion layer; and (v) a cathode gas and liquid flow field comprising a three-dimensional open-cell foamed structure suitable for gas and liquid diffusion, the cathode gas and liquid flow field juxtaposed to the bottom face of the gas and liquid diffusion layer; the fuel cell assembly being located within and integral to the central cavity of the distribution frame, and being located such that the gas and liquid flow field is contiguous to the air supply channels and the air and water outlet channels so as to form an edge-on connection with the air supply channels and the air and water outlet channels, and located such that the gas flow field is contiguous to the fuel supply channels so as to form an edge-on connection with the fuel supply channels.
[0017] One embodiment of fuel cell stack of the p.i. comprises: (a) a first end plate and a second end plate, the second end plate being aligned with the first end plate; (b) at least one fuel cell, the fuel cell being interposed between the first end plate and the second end plate and the fuel cell further comprising: (i) a distribution frame having: (A) an anode side, a cathode side and a central cavity suitable for housing an MEA; (B) at least 2 fuel inlet apertures, the fuel inlet apertures extending completely through the distribution frame and each fuel inlet aperture being located 180° from the other, and each fuel inlet aperture having an interior side; (C) an air inlet aperture, the air inlet aperture extending completely through the distribution frame and the air inlet aperture being located 90° from each fuel inlet aperture and 180° from an air and water outlet aperture, the air and water outlet aperture extending completely through the distribution frame, the air inlet aperture and the air and water outlet aperture each further having an interior side; (D) a plurality of fuel supply channels, the fuel supply channels located on the anode side of the distribution frame and extending from the interior side of each fuel inlet aperture to the central cavity and being integral to each fuel inlet aperture; (E) a plurality of air supply channels, the air supply channels located on the cathode side of the distribution frame and the air supply channels extending from the interior side of the air inlet aperture to the central cavity and being integral to the air inlet aperture; and (F) a plurality of air and water outlet channels, the air and water outlet channels located on the cathode side of the distribution frame, the air and water outlet channels extending from the interior side of the air and water outlet aperture to the central cavity, and being integral to the air and water outlet aperture; and (ii) a fuel cell assembly having: (A) an MEA, the MEA having two catalytic active layers, the MEA further having an anode side and a cathode side; (B) a gas diffusion layer, the gas diffusion layer having a top face and a bottom face, the bottom face of the gas diffusion layer juxtaposed to the anode side of the MEA; (C) a gas and liquid diffusion layer, the gas and liquid diffusion layer having a top face and a bottom face, the top face of the gas and liquid diffusion layer juxtaposed to the cathode side of the MEA; (D) an anode gas flow field comprising a three-dimensional open-cell foamed structure suitable for gas diffusion, the anode gas flow field juxtaposed to the top face of the gas diffusion layer; and (E) a cathode gas and liquid flow field comprising a three-dimensional open-cell foamed structure suitable for gas and liquid diffusion, the cathode gas and liquid flow field juxtaposed to the bottom face of the gas and liquid diffusion layer; the fuel cell assembly being located within and integral to the central cavity of the distribution frame, and being located such that the gas and liquid flow field is contiguous to the air supply channels and the air and water outlet channels so as to form an edge-on connection with the air supply channels and the air and water outlet channels, and located such that the gas flow field is contiguous to the fuel supply channels so as to form an edge-on connection with the fuel supply channels; and (c) a compression assembly.
[0018] Other advantages of the present invention will be apparent to those ordinarily skilled in the art in view of the following specification claims and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] A more complete understanding of the present embodiments and advantages thereof may be acquired by referring to the following description taken in conjunction with the accompanying drawings, in which like numbers indicate like features, and wherein:
[0020] [0020]FIG. 1 is a schematic of a typical PEM fuel cell assembly.
[0021] [0021]FIG. 2 is an illustration of a conventional frame for housing and supplying reactants to a fuel cell assembly.
[0022] [0022]FIG. 3 is a depiction of a distribution frame of the present invention housing a fuel cell assembly.
[0023] [0023]FIG. 4 is an exploded view of the distribution frame and a fuel cell assembly of the present invention.
[0024] [0024]FIG. 5 is a cross-sectional view of an internal foil assembly of the present invention.
[0025] [0025]FIG. 6 is an electron micrograph of a three-dimensional open-cell foamed cathode gas and liquid flow field with microchannels.
[0026] [0026]FIG. 6A is an electron micrograph of the three-dimensional open-cell foamed cathode gas and liquid flow field with microchannels of the present invention magnified 10 times.
[0027] [0027]FIG. 6B is an electron micrograph of the three-dimensional open-cell foamed cathode gas and liquid flow field with microchannels of the present invention magnified 20 times.
[0028] [0028]FIG. 7 is an electron micrograph of the connections between a three-dimensional open-cell foamed gas flow field and an internal foil in an internal foil assembly of the present invention.
[0029] [0029]FIG. 8 is an electron micrograph of the connections between the three-dimensional open-cell foamed gas flow field magnified 150 times.
[0030] [0030]FIG. 9 is an electron micrograph of two individual connections between the three-dimensional open-cell foamed gas flow field and the internal foil of an internal foil assembly of one embodiment of the present invention.
[0031] [0031]FIG. 10 is an electron micrograph of a conventional internal foil assembly formed using conventional techniques.
[0032] [0032]FIG. 11 is an illustration of the fuel side of a distribution frame for a fuel cell assembly of the present invention.
[0033] [0033]FIG. 12 is an illustration of the air side of a distribution frame for a fuel cell assembly of the present invention.
[0034] [0034]FIG. 13 is an illustration of a fuel cell stack assembly of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0035] [0035]FIG. 3 depicts one embodiment of an individual fuel cell assembly of the present invention. As shown in FIG. 3, fuel cell 11 is housed within distribution frame 10 . Distribution frame 10 not only houses fuel cell 11 , but also facilitates transportation of the fuel and the oxidant to the fuel cell necessary for the electrochemical exchange in the fuel cell. This individual fuel cell assembly can be combined with other fuel cell assemblies to form a fuel cell node, and ultimately a stack assembly, to provide higher voltages and current for power generation. Of note in FIG. 3 are fuel inlet 22 , fuel inlet 24 , air inlet 12 and air and water outlet 14 . The fuel inlets 22 and 24 , air inlet 12 , and air and water outlet 14 are apertures in the distribution frame extending completely through the distribution frame, and run perpendicular, or at 90° angles, from one another in the distribution frame to facilitate the efficient flow of the fuel and oxidant to and through the anode gas and liquid flow field and cathode gas flow field, respectively.
[0036] [0036]FIG. 4 more particularly illustrates the component parts of the fuel cell assembly of one embodiment of the present invention depicted in FIG. 3, specifically distribution frame 10 , primary internal foil assembly 64 , fuel cell 11 and secondary internal foil assembly 30 . Primary internal foil assembly 64 consists of primary anode gas flow field 52 , primary internal foil 54 and primary cathode gas and liquid flow field 56 . Primary internal foil 54 serves as a boundary layer between primary anode gas flow field 52 and primary cathode gas and liquid flow field 56 to keep air from flowing into the anode gas flow field from the cathode and water from flowing from the cathode gas and liquid flow field to the anode gas flow field. MEA 58 is composed of an electrolyte, primary cathode catalytic active layer 60 , and secondary anode catalytic active layer 62 . Any known MEAs may be used in the present invention. Conventional fluorocarbon based polymeric membranes are particularly suitable for the present invention-including Nafion membranes. Primary cathode catalytic active layer 60 is bonded to primary cathode gas and liquid flow field 56 when the fuel cell is assembled. Secondary internal foil 31 also serves as a boundary layer between the anode and cathode electrodes of the internal foil assembly as does primary internal foil 54 . Secondary anode catalytic active layer 62 is bonded to secondary anode gas flow field 29 when the fuel cell assembly is assembled. FIG. 4 illustrates the assembled fuel cell placed in distribution frame 10 wherein secondary cathode gas flow field 28 is in view. Secondary internal foil 31 is also illustrated in FIG. 3.
[0037] When the fuel cell assembly of the present invention is assembled as in the embodiments depicted in FIGS. 3 and 4, the procession of layers is: primary anode gas flow field 52 , primary internal foil 54 , primary cathode gas flow field 56 , MEA 58 , secondary anode gas flow field 29 , secondary internal foil 31 , and secondary cathode gas flow field 28 . This defines the elements of one fuel cell of the present invention terminated by internal foil assemblies. Primary cathode catalyst layer 60 and secondary anode catalyst layer 62 of the MEA shown in FIG. 4 may be comprised of platinum or a platinum/ruthenium catalyst. If platinum is used, it is typically combined with fibrous material, including suitable nonwovens, or suitable cotton muslin sheets or pieces of fabric. Primary cathode gas flow field 56 and secondary anode gas flow field 29 are bonded to primary cathode catalytic active layer 60 and secondary anode catalytic active layer 62 , respectively, through mechanical bonding means such as compression or adhesion. However, there is no need for excessive compressive force in the present invention to create the electrochemical connections between the catalytic active layers and the gas flow fields. Compression may be provided by any known means, such as a tie-rod assembly. In general, the compressive force on a fuel cell stack should be less than 100 psi.
[0038] [0038]FIG. 5 is a cross-section of an internal foil assembly of the present invention. Internal foil assembly 64 is comprised of three parts: anode gas flow field 66 , internal foil 68 , and cathode gas and liquid flow field 70 . The cross section of the anode gas flow field 66 may be preferably approximately half the size of cathode gas and liquid flow field 70 to accommodate the ratios of reactants necessary for the electrochemical exchange in the fuel cell. Both anode gas flow field 66 and cathode gas and liquid flow field 70 may be composed of a three-dimensional open-cell foamed structure suitable for gas diffusion that, preferably, may be plated with gold. In another embodiment of the present invention, cathode gas flow field 70 may be corrugated to create microchannels. FIG. 6 illustrates a corrugated cathode gas and liquid flow field of the present invention. These microchannels facilitate the removal of free water and excessive heat from the fuel cell assembly. When the fuel cell is placed in the distribution frame, these microchannels in the cathode gas and liquid flow field 70 run parallel to the air inlet and air and water outlet, and perpendicular to the fuel inlets. The vertical distance between the peak of a corrugation and the trough next to it, herein referred to as the pitch, should be at least ⅔ of the horizontal distance between a peak of one corrugation to the peak of the next corrugation, herein referred to as the run. Whereas, as shown in FIG. 5, anode gas flow field 66 is directly bonded to internal foil 68 ; in an alternative embodiment cathode gas and liquid flow field 70 is only bonded to the internal foil at the peaks of the corrugations. As shown in FIG. 6, the cathode gas and liquid flow field is therefore intermittently bonded to the internal foil at the peaks of the microchannels. This structure effectively manages the ternary reactions necessary for fuel cell operability by adequately removing the water and facilitating the movement of hydrogen and air. FIGS. 6A and 6B depict magnified views of the microchannels shown in FIG. 6.
[0039] Suitable construction materials for the three-dimensional open-cell foamed gas flow fields and gas and liquid flow fields are conducive to flow distribution and possess good electrical conductivity properties. These may include: plastics, carbon filament, stainless steel and its derivatives, epitaxial substrates, nickel and its alloys, gold and its alloys, and copper and its alloys. Iridium may also be used if it has sufficient electrochemical properties. In one embodiment of the present invention, the anode gas flow field and the cathode gas and liquid flow fields are made from open-cell foamed nickel. The open-cell foamed nickel flow fields are produced by electroplating nickel over a particulate plastic so that the voids created by the tangential intersections in the particulate plastic structure are filled with nickel. Although polystyrene may be used in this method of producing the foamed flow field structure, other materials, such as other particulate thermoplastic resinous materials, would also be suitable in this process. Another suitable material, for example, would be Isinglass. If nickel is used, the nickel may be enhanced with 2.0% by weight of cobalt. The addition of cobalt enhances the mechanical strength of the nickel and reduces the drawing properties of the nickel. The addition of cobalt also strengthens the lattice structure of the finished open-cell foamed flow field. Once the nickel has cooled, the polystyrene plastic may be blown out of the foam with hot carbon dioxide gas or air leaving a three-dimensional nickel open-cell foamed flow field structure having substantially five-sided geometrically-shaped orifices. The nickel foamed flow field is autocatalytically microplated with up to 15 microns of gold, iridium, copper or silver. Preferably, the flow field is microplated, with between 0.5 to 2.0 microns of gold.
[0040] [0040]FIGS. 7 and 8 are electron micrographs of a three-dimensional open-cell foamed flow field of the present invention wherein the substantially five-sided orifices are visible and have been plated with gold. The advantage obtained from utilizing a three-dimensional open cell foamed flow field in the present invention is that it enhances mass transfer within the flow fields. This is because the mass transfer rate is supplemented by the foamed flow field itself and its wicking ability, which allows the molecules to electromosaticaly move through the flow field. Another advantage associated with the foamed flow fields of the present invention is that they also facilitate the deposit of the reactants uniformly along the surface of the catalytic active layers. A further distinct advantage of the foamed flow fields over conventional serpentine arrangements is that the foamed flow fields enhance the ternary reactions of the fuel cell. The gold plating further enhances the electromosatic movement of the molecules through the flow fields by providing microridges, evident in FIGS. 7 and 8, on the surfaces of the foamed structure's orifices. These microridges facilitate the flow of the fuel, oxidant, and water in the flow fields. The gold plating enhances mass transfer by increasing the surface area of the foam by as much as a factor of nine. Another advantage of gold plating the foamed flow field of the present invention is that the leaflet potential of the gold preserves the structure of the foamed flow fields by preventing the flow fields from undergoing electrolysis. This enhances the life of the flow fields and the fuel cell assembly itself, making the fuel cell assemblies of the present invention suitable for residential and light-commercial uses.
[0041] As shown in FIG. 5, in internal foil assembly 64 , anode gas flow field 66 and cathode gas and liquid flow field 70 are attached to primary internal foil 68 through mechanical bonding, such as sintering, plating, pressing, rolling, drawing, or extruding. Another connections means would include laminating through electrochemical adhesives. This increases the electrical conductivity through the internal foil assembly by decreasing the air gap between the flow fields and the internal foil. Preferably, internal foil 68 is plated with gold as are the flow fields so as to create an undisturbed electrical connection between the flow fields and the internal foil. When a gold-plated nickel foam is used, an alloy of copper and silver should be used to sinter the gold plated, nickel foam to internal foil assembly 64 .
[0042] [0042]FIG. 9 is an electron micrograph of one embodiment of the internal foil assembly of one embodiment of the present invention illustrating the connection as shown in FIG. 5 between anode gas flow field 66 , cathode gas flow field 70 , and internal foil 68 , wherein all three elements have been gold plated. As can be particularly seen by the arrows in FIG. 9, the substantially five-sided orifices of the open-cell foamed gas flow fields are not deformed by the bonding process of the present invention. FIG. 10 comparatively illustrates the deformation the gas flow field suffer if bonded to the internal foil using conventional techniques. The electrically consistent connection achieved in the present invention between the flow fields and the internal foil provides for more efficient mass transfer in the internal foil assembly of the present invention.
[0043] Shown in FIG. 11 is one embodiment of the anode side of distribution frame 10 . Fuel inlet 12 and fuel inlet 14 provide the fuel to the fuel cell housed within the cavity of distribution frame 10 necessary for the electrochemical reaction. Specifically, the fuel is fed to the anode gas flow field through fuel supply channels 18 and 16 that stretch from the interior sides or surfaces of fuel inlet 12 and fuel inlet 14 , respectively. Fuel supply channels 18 and 16 are shaped such that the supply of the fuel to the anode is preferably maintained at a constant velocity, i.e., the channels are of sufficient length, width and depth to provide fuel to the anode at a constant velocity. The velocity of the fuel entering the anode gas flow field via fuel supply channels 18 and 16 may be less than the velocity of oxidant entering the cathode gas flow field via air supply channels 25 . The number of fuel supply channels in the distribution frame stoichiometrically balances the number of air supply channels so as to achieve a 2.0 to 1.0 to 2.8 to 1.0, preferably 2.0 to 1.0 to 2.4 to 1.0, air to fuel ratio. Fuel supply channels 18 and 16 also provide an edge-on connection between the fuel supply inlets and the anode gas flow field of the fuel cell housed within the cavity of the distribution frame to allow for enhanced dispersion of the fuel through the anode gas flow field. Suitable materials of construction for distribution frame 10 include nylon-6, 6, derivatives of nylon-6, 6, polyetheretherketone (“PEEK”), ABS styrene, mylar, textar, kevlar or any other nonconductive thermoplastic resin. Preferably, distribution frame 10 is formed from nylon-6, 6, and, if used in a stack assembly, the end plates of the fuel cell stack assembly are preferably formed from PEEK. Nylon-6, 6 is a particularly suitable material for distribution frame 10 because it dissipates electrical energy quickly so that it will not accumulate in the fuel cell assembly. It also has good compression properties. Distribution frame 10 is preferably substantially circular.
[0044] Shown in FIG. 12 is the cathode side of distribution frame 10 . Air is a necessary reactant for the electrochemical exchange, and may be fed to fuel cell 11 via air inlet 24 in combination with air supply channels 26 . Air supply channels 26 stretch from the interior surface or side of air inlet 24 to fuel cell 11 , and are of such sufficient size and shape that they enable air to be fed to the cathode gas flow field at a constant velocity, i.e., they are of sufficient height, width and depth. The number of fuel supply channels 18 and 16 will most often exceed the number of air supply channels 26 to maintain a stoichiometric balance of the reactants. Free water is formed continuously in the cathode gas and liquid flow field as a by-product of the electrochemical reaction. As described, the open-cell foamed of the cathode gas and liquid flow field facilitates the removal of this free water from the cathode gas and liquid flow field efficiently. In an alternative embodiment of the present wherein the cathode gas flow field is corrugated, the microchannels in the cathode gas flow field enhance free water removal from the system. Air and water outlet 22 and air and water outlet channels 25 facilitate the flow of this free water from fuel cell 11 to allow for optimal water management in the fuel cell, and to avoid flooding and the resultant loss in power. In a stack assembly, this free water may be transported for use in other parts of the fuel cell unit, unit here meaning the balance of plant assembly. Air and water outlet 22 and air and water outlet channels 25 also facilitate dissipation of the heat generated by the electrochemical reactions.
[0045] [0045]FIG. 13 is a cross-section of a fuel cell stack assembly shown generally at 200 that encompasses a plurality of fuel cell assemblies. Two or more individual fuel cell assemblies can be combined to form a node. Two or more nodes can be combined to form a fuel cell stack assembly. Typically, these individual fuel cells will be interposed between end plates, which are preferably substantially circular. Stacks can be placed in series to increase voltage. Stacks can be arranged in parallel to increase amperes. In one embodiment of the present invention, 1 end plate is used for every 6 fuel cell assemblies frames to provide desirable torsional properties to the fuel cell stack assembly.
[0046] Although the present disclosure has been described in detail, it should be understood that various changes, substitutions, and alterations can be made hereto without departing from the spirit and the scope of the invention as defined by the appended claims. | An improved proton exchange membrane fuel cell assembly and fuel cell stack assembly are provided for the economical and efficient production of electricity. The present invention comprises improved flow fields and reactant supply systems, which provide improved and more efficient mass transport of the reactants in the fuel cell and the fuel cell stack assembly. The improved flow fields comprise three-dimensional open-cell foamed metals that are preferably plated with gold. The improved reactant supply system comprises an improved distribution frame to house fuel cells wherein the reactants are directly connected to the improved flow fields. | 8 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] Not Applicable
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable
REFERENCE TO SEQUENCE LISTING
[0003] Not Applicable
BACKGROUND OF THE INVENTION
[0004] Lubricants are critical in getting electrical switches to meet their life and operating specifications. Choosing the right one requires a full understanding of the switch and its environment. Lubricants improve switch performance in three ways. Primarily, they prevent environmental and galvanic corrosion on switch contacts. Airborne contaminants attack metals, causing oxides to gradually build up in pores until they reach the surface, where they impede current flow. Non-noble contact surfaces and switches made of dissimilar metals are especially susceptible to moisture, oxygen, and aggressive gases. Even noble-metal plating is at risk if it's worn or porous.
[0005] Lubricants also minimize wear, especially on sliding electrical contacts which see repetitive cycling or arc damage, two common causes of failures. Though evidence suggests lubricants change or reduce arc patterns, the lubricant's real job on sliding contacts is to separate the surfaces during operation and keep debris out of the contact area. Otherwise, the microscopic wear particles oxidize quickly, turning into insulators. Buildup of this oxide grit also accelerates wear. In general, hydrocarbon lubricants work best at wear prevention because their molecular structure is more rigid than other base oils. Proper lubricants strike a balance between preventing wear and maintaining electrical continuity.
[0006] And finally, lubricants reduce the friction between switch components, thus reducing the amount of force needed to activate a switch. Lubricants usually ensure a coefficient of friction of 0.1 or less, which means it takes little force to operate a device with a high preload. This can be important in switches where high normal forces ensure low contact resistance and a stable signal or power path. Lubrication is also mechanically important because it gives the end user smooth, uniform operation.
[0007] Damping greases (high-viscosity lubricants) are used to provide drag and give switches a “high-quality” feel. Although silicones historically have been used as damping greases, new high-molecularweight polymers offer a similar feel without fear of silicone migration, which is more than an aesthetic problem. Under arcing, silicone degrades to silicon dioxide (sand), an abrasive and insulating by-product that destroys contacts quickly.
[0008] Safety when working around high voltage switches is a major concern. Having to manually apply lubrication to transformers and high voltage electrical switches poses a safety and health risk, but it is necessary to lubricate because high current levels also raise the issue of arcing. Under an arc, temperatures can reach 1,000 C. At that temperature, most metals become molten and most hydrocarbons polymerize, becoming a tacky, viscous, insulating film that is not easily displaced. No material can withstand this abuse, and eventually the switch fails, causing an open circuit. To prevent arcing, choose a lubricant with the longest life under such conditions. In theory, lubricants that vaporize instead of polymerize—such as polyglycols and PFPEs—work better because they leave no insulating residue. However, as a lubricant vaporizes, less remains to lubricate.
[0009] The ability to apply a lubricating substance from a safe distance from the apparatus is ideal.
[0010] The impact-rupturable pellet containing the lubricating substance as described in this invention are set into projectile motion with the shell substantially intact at a velocity sufficient to create the force permitting rupture of the shell and release of the liquid dye composition therein upon physical impact with the target surface. Typically, the suitable velocity range is from about 200 ft/sec to about 400 ft/sec, preferably within a range from about 300 ft/sec to about 350 ft/sec. Such devices are typically in the form of a gun assembly adapted for use with the pellet. The gun assembly is commonly referred to as a lubricating pellet gun or “marker.” Suitable lubricating pellet guns include commercially available models such as those from Brass Eagle (Bentonville, Ark.). Accordingly in use, the impact-rupturable capsule is removed from a container and loaded into the lubricating pellet gun. The gun is aimed at the intended target and fired, ejecting the impact-rupturable capsule substantially intact at high speed toward the target through the use of pressurized CO.sub.2 or N.sub.2. Upon impact on the target surface, the shell ruptures thereby releasing the liquid contents within onto the surface.
SUMMARY OF THE INVENTION
[0011] The present invention makes it possible to safely apply a lubricating substance on a target which is normally difficult to get access to or poses a health or safety risk for manual application of the lubricating substance. With the present invention, a nonsolid lubricant such as oil or grease is encapsulated in frangible or impact-rupturable pellet. Since an air gun or other pneumatic device may be used, a standard, 0.68 inch diameter is the preferred size of the pellet, but sizes can vary depending on the size of the target and the pellet delivery system used.
[0012] The body of the pellet, or shell is frangible and/or biodegradable. The engagement of pressure or force on the pellet causes the shell to break and frees the nonsolid lubricant from the broken pellet and such freed lubricant lubricates the target surface. Although encapsulation is particularly adapted for nonsolid lubricants, it can be used for any lubricant, the release or exposure of which should be delayed until impact.
[0013] As this invention makes it possible to employ nonsolid lubricants in pellet of this type, the environmental shortcomings of dry lubricants are no longer a limiting factor to the extent that nonsolid lubricants, which overcome these shortcomings, are available.
[0014] The dry lubricant would perform a lubricating function in the middle temperature range but would be substantially inoperative as a lubricant in the low temperature range.
[0015] Yet another object of the present invention is to provide pellets that are fabricated from water-based instead of an oil-based material. A feature of the water based pellets is a soluble polymer shell. Another feature of the water based pellets is an insoluble coating on an inner wall of the shell. An advantage of the water based pellets is that the shell biodegrades relatively fast. Another advantage of the water based pellets is that the shell will not degrade or dissolve when a water based or lubricating material is disposed within a cavity defined by the shell, due to the lubricating material engaging only the insoluble coating. Another object of the present invention is to provide water based pellets that do not harm landscape exposed to pellet activity. An advantage of the water based pellets is that the ph level of the lubricating material is substantially equal to the ph level of water (i.e. 7.0). Another advantage of the water based pellets is that the lubricating material biodegrades relatively fast.
[0016] Another object of the present invention is to provide water based pellets that are relatively easy and inexpensive to fabricate. Another advantage of the water based pellet is that when the pellet is forcibly urged toward a target, the lubricating material is in an active liquid state that promotes the dispersing of the lubricating material (and pigments suspended in the lubricating material) upon a target surface.
[0017] The invention further provides a method for fabricating pellets, said method comprising the steps of fabricating a plurality of relatively rigid spheres of lubricating fill material; coating, dipping or spraying said lubricating material spheres with an insoluble material; and forming a shell about said coated lubricating spheres, whereby a spherical pellet is fabricated that ultimately engages a target, whereupon, said shell ruptures thereby promoting the engagement of a now substantially liquid lubricating material upon the target.
[0018] Soluble outer shell materials, such as gelatin, may be used.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] These and other objects, advantages and novel features of the present invention, as well as details of an illustrative embodiment thereof, will be more fully understood from the following detailed description and attached drawings, wherein:
[0020] FIG. 1 is a front elevation, partial phantom-partial cutaway view of a seamless lubricating pellet having a lubricating substance in an inner cavity in accordance with the present invention.
[0021] FIG. 2 is a front elevation, partial phantom-partial cutaway view of the lubricating pellet of FIG. 1 but with a seam (fusing line) from where the two hemispheres are connected to form the inner cavity in accordance with the present invention.
[0022] FIG. 3 is a front elevation, partial phantom-partial cutaway view of a lubricating pellet having an injection or disposition point in which the inner cavity is filled with the lubricating substance in accordance with the present invention.
[0023] FIG. 4 is a front elevation, partial phantom-partial cutaway view of a lubricating pellet showing the thickness of the shell and outer surface of the pellet in which the inner cavity is filled with a lubricating substance.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0024] Referring to FIG. 1 , a water-based lubricating pellet in accordance with the present invention is depicted and denoted as numeral 10 . The lubricating pellet 10 includes a shell 12 of soluble materials (usually gelatin) defining an interior cavity 14 , and a lubricating material 16 disposed and disbursed within the cavity 14 such that when the lubricating pellet 10 is forcibly ejected from a lubricating pellet gun (not depicted) ultimately engaging a target causing the shell 12 to rupture and the lubricating substance 16 to disburse upon the target surface.
[0025] The outer shell 12 may be comprised of soluble such as gelatin or insoluble materials such as plastics, waxes and hardeners such as carnauba, candelilla, bees, paraffin, stearic acid, synthetic polymers, polyesters, polylactic acid, starch copolymers, high molecular weight polyvinylalcohol, unstabalized polyethelyne, unstabilized polypropylene, polystyrene, and combinations thereof. In this embodiment it is intended that when the pellet is projected at sufficient force that the shell 12 fractures and expels the lubricating substance 16 .
[0026] The shell 12 is fabricated from a gelatin cast into a rolled sheet, or an extrusion grade biodegradable polymer, extrusion-compounded with inert processing aids and pigments, and extrusion cast into a rolled sheet of dimensions well known to those of ordinary skill in the art. Suitable polymers include, but are not limited to biodegradable polyesters, polylactic acid, starch copolymers and polymer blends, high molecular weight polyvinylalcohol, unstabilized polyethylene, unstabilized polypropylene and polystyrene, and combinations thereof. Coloring pigments may be included in the shell 12 .
[0027] An alternative method for fabricating the lubricating pellets 10 includes two congruent sets of molds with selected configurations (usually spherical). The molds are joined together to form an interior cavity 14 to allow the lubricating substance 16 to be suspended within the shell 12 . The lubricating pellet 10 can be ejected or projected from an air powered gun or other transmittal device. The shell 12 is capable of breaking or rupturing upon a target, whereupon, the rupturing of the shell 12 releases the lubricating substance 16 upon the target.
[0028] Referring now to FIG. 2 , an alternative embodiment 20 in accordance with the present invention is depicted. The alternative embodiment 20 includes an impact-rupturable solid spherical outer shell 22 formed from two hemispheres, right hemisphere 21 and left hemisphere 23 , fused together at fusing line 25 to define the inner cavity 24 containing a lubricating substance 26 .
[0029] The lubricating pellet 20 is manufactured by first feeding a polymer sheet material onto a heated, horizontal vacuum thermoforming mold. The thermo forming molds contain multiple cavities, in the shape of lubricating pellet half-shells. Any caliber of lubricating pellets may be manufactured by adjusting the thermoforming mold cavity geometries to the desired dimensions. By using heated vacuum molds and plug assistance, to ensure uniform shell wall thickness, webs of lubricating pellet hemispheres are thermoformed. The hemisphere cavities are then filled with the lubricating material 26 using precision metering nozzles so that the right hemisphere 21 and the left hemisphere 23 is completely filled, level with the top of the hemisphere. The filling rate and shear of the nozzle is chosen so that the lubricating material 26 thins enough during injection to self-level in the interior cavity 24 of the hemispheres. The two filled hemispheres are then turned, either horizontal or vertical, so that the right hemisphere 21 and left hemisphere 23 oppose each other and the half-shells are then quickly brought together and compressed with a fusing line 25 , thus fusing the two filled hemispheres together and forming the lubricating pellet 20 .
[0030] Other methods of fusing the hemispheres for sealing may be used such as heated molds and ultrasonic welding. Alternatively, the lubricating pellet hemispheres or half-shells may be fused using any suitable adhesive material or fusing methods such as radio frequency sealing along the fusing line.
[0031] Referring now to FIG. 3 , a third embodiment 30 in accordance with the present invention is depicted. The third embodiment includes a homogenous outer shell 32 that is penetrated at an injection or depiction point 38 at which the lubricating substance 36 is instilled into the inner cavity 34 . The injection or depiction point is then sealed to prevent leakage of the lubricating substance. Any sealing method may be used, similar to the fusing methods discussed above, to seal said injection point
[0032] The lubricating substance 36 disposed within the spherical shell 32 may include but is not limited to, polyethylene glycols, waxes, oils, and greases.
[0033] Referring to FIG. 4 , a fourth embodiment of the pellet 40 is depicted. The pellet 40 includes a shell 32 having a outer surface 43 that is of a uniform thickness 45 which encloses the lubricating substance 46 .
[0034] The foregoing description is for purposes of illustration only and is not intended to limit the scope of protection accorded this invention. The scope of protection is to be measured by the claims, which should be interpreted as broadly as the inventive contribution permits.
[0035] Although exemplary embodiments of the invention have been shown and described, many changes, modifications and substitutions may be made by one having ordinary skill in the art without necessarily departing from the spirit and scope of this invention. | A lubricating pellet includes an impact-rupturable shell defining an interior cavity, a lubricating substance consisting of grease or oil or other lubricating substance disposed throughout the interior cavity and contained within by said shell, providing a impact-rupturable container when the lubricating pellet is ejected from a pellet discharge device, hitting an intended target and disbursing the lubricating substance onto the target. | 2 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] This is a division of copending application Ser. No. 09/762,789 filed Feb. 13, 2001.
BACKGROUND OF THE INVENTION
[0002] The invention relates to a pump for delivering a fluid, in particular a rotary vane pump, of the type having a delivery device accommodated in a casing, a casing cover on one end face, and a bearing flange adjoining the casing on the opposite side of the casing cover. The delivery device serves to displace the fluid from a suction zone to a delivery zone of the pump.
[0003] The pump of the described type may further have a feed channel for the fluid, which is formed in the casing and extends into the suction side of the delivery device, and an injector device serving to deliver the fluid, wherein the injector device injects the fluid under high pressure into the fluid exiting from the feed channel into an upstream jet chamber, thereby entraining or accelerating same.
[0004] Pumps of the kind under discussion, for example rotary vane pumps, are adequately known from practice, for example from DE 39 28 029 A1, DE 41 22 433 C2, and DE 41 38 516 A1.
[0005] Pumps of the described type are used, for example in power steering systems, and they deliver a special oil for purposes of assisting the steering force being applied to the steering wheel of an automobile. Preferably, the pumps are rotary vane pumps, which take in oil from a reservoir provided outside of the pump, preferably an external tank. Normally, such pumps are equipped with a flow control valve, which permits directing oil from the high-pressure or delivery zone, to the suction zone of the pump. Effective a certain rotational speed of pump and with a constantly adjustable delivery, the flow control valve opens a discharge bore, through which oil under high pressure is allowed to leave. The oil enters the suction chamber of the delivery device.
[0006] On the delivery side of the pump, leakages occur constantly, so that special measures are needed for removing the leakage oil. To this end, leakage paths leading to the suction side are provided in pumps of the art, so that the leakage oil is again supplied to the oil directed from the tank into the pump. Measures realized so far with respect to leakage paths or leakage oil channels involve a significant manufacturing expenditure and, consequently, represent quite a relevant cost factor in the manufacture of the pump.
[0007] U.S. Pat. No. 5,496,152 discloses a rotary vane pump, which comprises for purposes of realizing as much as possible a cavitation-free operation, a very special arrangement for delivering the tank oil, namely an injector device, which operates similarly to a water jet pump. The injector device receives fluid under high pressure, which is supplied to the injector device from the high-pressure side. The injector device injects this high-pressure fluid into the stagnant fluid from the feed channel, namely in the region of a jet chamber upstream of the delivery device. As a result, the fluid coming from the tank is entrained or accelerated, and enters from there, via a further channel system, the suction side of the delivery device.
[0008] However, the technique disclosed in U.S. Pat. No. 5,496,152 and relating to the use of an injector device is problematic in that this injector device operates only on one side of the casing with a jet nozzle, from where it must deliver the fluid coming from the tank to both sides of the casing, in the respective suction zone, for purposes of making the fluid available in an adequate amount on both sides of the casing to the suction chambers associated to both sides of the delivery device or rotary group. Due to the differently long flow paths to the suction chambers arranged on both sides, different pressure conditions occur in the fluid, which results again in a varying supply of fluid to the suction chambers on both sides. This leads to cavitation or damage resulting from cavitation, in particular in the case of high delivery rates of the pump. Furthermore, a uniform filling of the suction zones on both sides is questionable.
[0009] It is the object of the present invention to improve and further develop a pump of the described type such that it enables a reliable removal of the leakage oil on the delivery side, while simultaneously reducing constructional and manufacturing measures. Furthermore, it is desired to ensure a uniform admission of fluid to the cells of the delivery device. Damage due to cavitation is to be prevented effectively.
SUMMARY OF THE INVENTION
[0010] The above and other objects and advantages of the invention are achieved by the provision of a pump of the described type wherein a seal is disposed between at least one of (1) the casing cover and one end face of the casing and (2) the bearing flange and the other end face of the cover. The fluid leakage path extends between the delivery zone and the suction zone, with at least a portion of the leakage path extending along the inner side of the seal.
[0011] In accordance with the invention, it has been recognized that it is possible to design and construct the leakage path, so that it extends at least in sections parallel to the seal. The arrangement of the leakage path close to the seal relieves the seal on the delivery side. Consequently, the arrangement of the seal achieves not only a reliable removal of the fluid or leakage oil, but also a reliable relief of the seal, thereby assisting the sealing effect in the long run. The leakage path is provided wherever leakage oil emerges, which is to be removed on the delivery side. Consequently, the leakage path extends at least in sections parallel to the seal, namely on the inner side or media side of the seal.
[0012] From manufacturing aspects, it will be quite especially advantageous, when a groove that is anyway provided for the seal, is used as leakage path. This groove is formed either in the casing cover or, if present, in the bearing flange or in the respective end face of the casing, and it is actually used for inserting or receiving the seal. For example, the groove may be made integral with the respective component.
[0013] To use this groove as leakage path, the groove is made at least in part wider than the seal toward the inner side of the seal or media side, so that the groove forms on the inner side of the seal the leakage path that extends parallel to the seal directly adjacent thereto.
[0014] Within the scope of such a constructional measure, the seal is directly relieved only on its inner side. At the same time, it is lubricated on its inner side and cooled, if need arises. In the case of a wide construction of the groove, the latter has a double function, namely, on the one hand, the accommodation of the seal, and on the other hand, the arrangement of a leakage path or leakage channel. Since the groove is needed anyway for receiving the seal, manufacturing expenditure is reduced quite considerably. Furthermore, this measure reduces the overall space needed as a whole, so that it assists a miniturization of the pump.
[0015] Very advantageously, the groove is designed and constructed as a self-contained, peripheral annular groove, so that a gasket is suitable for use as a seal. As previously stated, the groove may be widened over its entire length, so that the leakage path extends over the entire length of the seal on the inner side of the seal or media side. Likewise, it is possible to extend the leakage path as a widening of the groove only in part over the length of the groove, namely wherever leakage oil emerges that is to be removed.
[0016] Concretely, the groove could be made as a simple groove with a substantially widened groove bottom (at any rate wider than the normal groove for receiving the seal), so that the seal or gasket can be positioned in the outer region of the groove in contact with the outer groove wall. This results automatically from the dimensioning of the groove on the one hand and the gasket on the other.
[0017] It is likewise possible to make the groove stepped toward the groove bottom, with the seal being arranged in the outer step of the groove. Advantageously, the outer groove portion that receives the seal is submerged. Furthermore, it is possible to make the groove as a kind of double groove, with a partition extending between the groove portions and separating same at least in part or to a great extent. According to the foregoing description, one would insert the seal or gasket into the outer groove portion. Advantageously, even this groove portion may be made at least slightly larger than the seal. The inner groove portion will serve as a leakage path.
[0018] In an advantageous manner, the widened portion of the groove, i.e. the leakage path extending parallel to the seal, communicates at least in one location with the suction side of the pump for purposes of effectively removing from the delivery side leakage oil that collects in the leakage path. In this process, the leakage oil is supplied directly to the suction side of the pump and is there again mixed with the tank oil. Naturally, in accordance with the emergence of leakage oil, it is also possible to provide a plurality of flow connections between the leakage path and the suction side. These connections may be bores, recesses, or even a kind of labyrinth, which extends from the groove toward the suction side. At any rate, it is to be ensured in this case that the leakage oil collecting in the leakage path or in the groove is adequately removed toward the suction side.
[0019] In connection with the foregoing measures, it will be of advantage, when the entire delivery side, i.e., the high pressure prevailing in the pump, is sealed at least quite predominantly within the interior of the casing, and/or directly adjacent thereto. Within the scope of such a measure, the high pressure within the bore formed for the rotary group of the vane pump is sealed, so that a “real” high pressure no longer prevails outside of this bore, or far removed therefrom, and thus away from the interior of the casing. Consequently, the seal extending in the widened groove is no longer exposed to the “real” high pressure, as is the case with conventional pumps of the species-forming kind, so that likewise to this extent the arrangement of the leakage path is assisted on the one hand with the leakage path itself and on the other hand with the there adjoining seal.
[0020] Further seals that are used for sealing the delivery side are operative toward the casing cover and optionally toward the bearing flange. Likewise in this instance, the seals may be conventional gaskets, which may moreover be provided likewise with a special leakage path, namely each in the form of a widened groove. Last but not least, it is possible to construct even a plurality of grooves, each as a special leakage path, which are used for inserting a seal, for purposes of being able to ensure a particularly effective removal as regards the leakage oil.
[0021] The pump of the present invention also accomplishes the foregoing objects by the provision of a pump wherein the feed channel for the fluid includes a subchannel which terminates in a jet chamber on both sides of the delivery device, and wherein an injector device injects into both of the jet chambers, each time with jet nozzles, so that at least one jet nozzle of the injector device is directed into each of the two jet chambers. Accordingly, the injector device comprises injectors that are directed into each of the two jet chambers, i.e., a total of two injectors. These injectors in turn inject with at least one jet nozzle.
[0022] The present invention has recognized that one should make available the same amount of fluid under identical conditions on both sides of the casing in each respective suction zone of the delivery device, i.e., directly upstream of the suction chambers of the delivery device. Furthermore, it has been recognized that this kind of delivery of the fluid is possible, only when the feed channel for supplying the fluid advancing from the tank also terminates in fact on both sides of the delivery device with respectively one subchannel in a jet chamber serving to accelerate the fluid. The acceleration of the there exiting fluid occurs, on both sides of the casing, in a conventional manner with the use of an injector device which, distinct from the previously described prior art, injects bilaterally, i.e., toward both sides of the casing, with one jet nozzle each into the respective jet chamber. To this end, one jet nozzle of the injector device is directed into each to the two jet chambers, so that as a result of injecting the high-pressure fluid, the fluid coming from the tank is accelerated or entrained.
[0023] In an advantageous manner, the injector device or its inlet is arranged substantially in the center of the casing above the delivery device. Such a central arrangement of the injector device has the advantage that the paths extending on both sides of the delivery device for accelerating on the one hand the fluid coming from the tank and on the other hand the high-pressure fluid being used for the injection, have approximately the same length. In a corresponding manner, the fluid entering the suction zones of the delivery device on both sides is under the same pressure, so that it is possible to admit fluid to the delivery device uniformly on both sides.
[0024] Specifically and within the scope of a particularly advantageous configuration, the jet nozzles are aligned such that the fluid injected under high pressure via the jet nozzle impacts upon the fluid being accelerated in the direction of its flow or at an acute angle with the direction of its flow. This again assists the acceleration of the fluid coming from the tank, with the high-pressure fluid being distributed already within the injector device to both jet nozzles with a high kinetic energy of the fluid being used for the injection.
[0025] As regards the jet nozzles, it will be of advantage, when same have an approximately round shape, so that upon its exit, the fluid forms a kind of jet jacket or cylindrical/conical jet jacket. In comparison with a thin fine jet, a larger contact surface results, which is present twice due to the injection by means of the jet nozzles on both sides. Last but not least, the fluid enters the jet nozzles of the injector device via discharge bores on both sides.
[0026] Furthermore, it is important that the subchannels extending from the feed channel that is divided on both sides of the delivery device, and carrying the fluid coming from the tank, have approximately the same length, so that likewise to this extent the same distances are covered by the fluid coming from the tank. After leaving the subchannels, the oil coming from the tank receives the oil injected under high pressure and with a high kinetic energy. As a result, it is accelerated in a way similar to the case of a water jet pump.
[0027] Advantageously, the two subchannels of the feed channel which are directed toward the opposite sides of the delivery device, are made not only of the same length, but also have the same configuration. Preferably, the two subchannels are substantially mirror images of each other.
[0028] On the one side of the casing, the pump comprises a cover on its end face, and on the other side of the casing a bearing flange, provided same is needed. To this extent, it is possible that the jet chamber formed on both sides of the delivery device is at least largely integral with the casing cover and bearing flange, respectively. Likewise, it is possible that the jet chamber is associated to the actual casing and defined by the inside wall of the casing cover on the one hand and the inside wall of the bearing flange on the other hand. Both variants are realizable.
[0029] As previously stated, the fluid coming from the tank is divided in accordance with the invention on both sides of the delivery device. On these two sides of the delivery device, the fluid undergoes acceleration by injection into the respective jet chamber. In a particularly advantageous manner, the nozzle jets are inclined downward at an angle deviating as much as possible from 90°, preferably at an acute angle, and directed to the wall of the casing and/or bearing flange opposite to the outlet of the feed channel, so that the accelerated fluid impacts thereupon with a high energy, and escapes to both sides in accordance with the contour of the wall of the casing and/or bearing flange. Consequently, the fluid undergoes another distribution, namely on both sides of the delivery device, again over two separate flow paths on both sides of the central bore provided in the casing for the delivery device or the rotary group that forms the delivery device.
[0030] In an advantageous manner, the wall of the casing and, optionally, the wall of the bearing flange is designed and constructed such that it distributes the there-impacting and accelerated fluid approximately equally by a lateral runoff, and directs it in the way of a guiding device at least largely into suction channels formed on both sides. These suction channels lead to the direct suction zone of the delivery device. Specifically, the suction channels lead directly to the suction chambers of the delivery device, along two separate flow paths on both sides of the delivery device, so that the suction chambers of the delivery device are supplied in four separate locations with fluid under the same pressure and with the same volume of fluid, thereby ensuring a uniform admission of fluid to the delivery device.
[0031] Furthermore, it will be very advantageous, when the suction channels leading to the suction chambers are made at least largely of the same length to avoid varying pressure losses in the fluid.
[0032] In a further advantageous manner, a pressure control pilot is provided, which serves as an overload protection for limiting a maximum operating pressure on the high-pressure side. To this end the pressure pilot receives from the high-pressure side fluid, which is to be returned after flowing through the pressure control pilot. In a further advantageous manner, the feed channel communicates to this end with the pressure control pilot for returning the pilot oil. This flow connection may be realized in an advantageous manner, preferably via a channel labyrinth that is made integral with the casing, and/or the casing cover, and/or the bearing flange. At any rate, it will be of advantage, when this fluid is returned to the circulation system together with the fluid coming from the tank, directly upstream of the range of action of the injector device. Likewise, it is possible to supply to the fluid coming from the tank leakage oil, which is bound to emerge on the high-pressure side. To this end, leakage oil channels or a corresponding labyrinth of channels are provided, which carry the leakage oil from different collection points into the feed channel.
[0033] There exist various possibilities of improving and further developing the teaching of the present invention in an advantageous manner. To this end, reference may be made to the following description of embodiments of the invention with reference to the drawing. Likwise, in conjunction with the description of preferred embodiments of the invention with reference to the drawing, generally preferred improvements and further developments of the teaching are described in greater detail.
BRIEF DESCRIPTION OF THE DRAWINGS
[0034] In the drawing:
[0035] [0035]FIG. 1 is a schematic sectional side view of an embodiment of a rotary vane pump which embodies the invention;
[0036] [0036]FIG. 2 is an end face view of the pump of FIG. 1, with a casing cover removed, wherein a groove forming a leakage path is made integral with the end face of the pump casing;
[0037] [0037]FIG. 3 is a schematic inside view of a bearing flange with an integral groove, but without a seal;
[0038] [0038]FIG. 4 shows in three schematic views, one below the other, three different embodiments of the groove comprising the leakage path;
[0039] [0039]FIG. 5 is a schematic sectional side view of a further embodiment of a rotary vane pump;
[0040] [0040]FIG. 6 is a schematic sectional side view of the pump of FIG. 5, without casing cover, without bearing flange, and without delivery device;
[0041] [0041]FIG. 7 is an end face view of the pump of FIG. 6 with the casing cover removed, which shows the outlet of a feed channel and of an injector device into a jet chamber; and
[0042] [0042]FIG. 8 is a schematic inside view of the bearing flange, whose wall is impacted by the accelerated fluid.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0043] [0043]FIG. 1 is a simplified illustration of a rotary vane pump in a sectional side view. Specifically, the pump is a vane pump with a rotary group 1 or delivery device not described in greater detail. As regards the special configuration of such a rotary group 1 reference may be made, for example, to DE 39 28 029 A1.
[0044] The illustrated pump comprises as essential components, a casing 2 and a delivery device accommodated within an interior chamber formed within the casing 2 . This delivery device is the aforesaid rotary group 1 . The casing 2 comprises the interior chamber and opposite sides. A suction zone 12 is defined on each of the sides, and a delivery zone 11 is defined on at least one of the sides. On the end faces, a casing cover 3 closing the casing 2 is provided on one side, and on the other side, the side opposite to the casing cover 3 , a bearing flange 4 closes the casing 2 .
[0045] Between the casing 2 and the casing cover 3 on the one hand, and between the casing 2 and the bearing flange 4 on the other hand, an outwardly operative seal 5 , 6 is arranged. The seal 5 , which is operative toward the casing cover 3 is inserted into a groove 8 formed in an end face 7 of the casing 2 . On the other side of the casing 2 , the seal 6 is associated to the bearing flange 4 or inserted into a groove 9 integral with the bearing flange 4 . It is likewise possible to incorporate the groove 9 in an end face 10 of the casing 2 .
[0046] It is already known from the state of the art to provide between a delivery zone 11 and a suction zone 12 of the pump, a leakage path for the fluid, namely a leakage path for leakage oil emerging on the delivery zone that is to be delivered to the suction zone.
[0047] In accordance with the invention the leakage path 13 is formed on the inner side of the seal at least in sections parallel to the seal 5 , 6 .
[0048] As best seen in FIG. 2, the groove 8 is made wider than the seal 5 for forming the leakage path 13 , so that the leakage path 13 is formed on an inner side 14 of the seal parallel to the seal 5 . Likewise, the leakage path 13 is formed by the groove 9 in bearing flange 4 , with the seal 6 not being separately shown in the illustration of the bearing flange 4 in FIG. 3.
[0049] FIGS. 1 - 4 show jointly that the grooves 8 , 9 are designed and constructed as self-contained annular grooves. Accordingly, the seals 5 , 6 are realized as gaskets, with the leakage path 13 extending only over those sections of the grooves 8 , 9 , where leakage oil collects and needs to be removed. Only there is the leakage path 13 made integral with the grooves 8 , 9 . As regards the groove 8 formed in casing cover 3 , this is best seen in FIG. 2.
[0050] As further indicated in FIG. 2, the widened portion of groove 8 , which forms leakage path 13 , communicates with the suction zone 12 of the pump via an integral leakage oil channel 15 . FIG. 2 further indicates, how a leakage oil 16 enters the leakage path 13 , parallel to seal 5 , i.e., how it enters groove 8 , and how the leakage oil 16 is supplied from there, via leakage oil channel 15 , to suction zone 12 and, thus, to the tank oil.
[0051] Furthermore, as indicated in FIG. 1, the delivery zone 11 , i.e., the high pressure, is sealed at least quite predominantly inside the interior 17 of the casing or directly adjacent thereto. To this end, seals 18 , 19 , 20 , 21 are provided, which are operative toward casing cover 3 and toward bearing flange 4 . These seals are likewise gaskets and/or combination seals. Consequently, the first-mentioned seals 5 , 6 are exposed to a substantially lesser pressure, close to the pressure on the suction side or the tank pressure, which assists the sealing effect of the pump as a whole quite considerably.
[0052] [0052]FIG. 4 shows three concrete configurations of the groove. The groove may be both the groove 8 formed in the end face 7 of casing 2 and the groove 9 formed in bearing flange 4 .
[0053] In the upper illustration, FIG. 4 shows that the groove 8 or 9 for forming the leakage path 13 is made substantially wider than is needed for receiving seal 5 or 6 . As a result of this wider construction, the leakage path 13 is formed directly adjacent seal 5 or 6 , respectively on the inner side of pressure.
[0054] The embodiment below thereof, as seen in the center of FIG. 4, shows a stepped configuration of the groove 8 or 9 , with the seal 5 or 6 being arranged in the lower-lying groove bottom. The leakage path 13 extends on a somewhat higher level than the groove bottom of the lower lying groove region, which receives seal 5 or 6 .
[0055] The lowest illustration in FIG. 4 shows a bipartite groove 8 or 9 . Within the scope of this embodiment, the leakage path 13 is separated by a partition 22 from the region of the groove 8 or 9 , which receives the seal 5 or 6 . This partition 22 is made lower than an outside wall 23 of groove 8 or 9 and leakage path 13 , respectively, so that in the case of an adequate amount of leakage oil, same is able to reach directly seal 5 or 6 .
[0056] As best seen in FIGS. 5 and 6, a feed channel 113 for the fluid extends into the suction zone 12 . Furthermore, an injector device 114 serving to deliver a fluid is provided, which operates in a fashion similar to a water jet pump. This injector device 114 injects a high-pressure fluid into a jet chamber 115 upstream of the delivery device 1 , and there into the fluid exiting from the feed channel 113 , thereby accelerating or entraining the fluid.
[0057] On both sides of the delivery device 1 , the feed channel 113 terminates respectively with one subchannel 116 into a separate jet chamber 115 . The injector device 114 injects toward the two sides, so that one jet nozzle 117 of the injector device 114 is directed into each of the two jet chambers 115 .
[0058] [0058]FIGS. 5 and 6 show jointly that the injector device 114 is arranged in the center above the delivery device 1 which is housed in the casing 2 . In this arrangement, the jet nozzles 117 are aligned such that the fluid injected under high pressure via the jet nozzle 117 impacts upon the fluid being accelerated approximately in the flow direction thereof, thereby assisting again an acceleration of the fluid coming from the tank. The fluid reaches the two jet nozzles 117 via the feed channel 113 , valve bore 125 , and discharge bores 126 .
[0059] As further shown in FIGS. 5 and 6, the subchannels 116 of feed channel 113 that is divided on both sides of delivery device 1 , are approximately of the same length, since the feed channel 113 is likewise evenly divided approximately in the center above the delivery device 1 .
[0060] As can be noted from FIG. 5, the jet chamber 115 formed on both sides of the delivery device 1 is largely made integral with casing cover 3 on the one side and with bearing flange 4 on the other side. The jet nozzles 117 are orthogonally directed toward a wall 118 of casing cover 3 opposite to the outlet of feed channel 113 on the one side, and toward a wall 119 of bearing flange 4 opposite to the outlet of feed channel 113 .
[0061] According to the illustration of FIG. 8, the wall 119 of bearing flange 4 is designed and constructed such that it divides the there impacting and accelerated fluid approximately evenly by a lateral runoff. The flow path of the fluid is indicated at numeral 120 . Last but not least, the walls 118 , 119 direct the fluid in the fashion of a guiding device into suction channels 121 formed on both sides, so that the fluid is divided one more time. The suction channels 121 lead to suction chambers of delivery device 1 . These suction chambers are arranged downstream of a direct suction zone 122 of delivery device 1 .
[0062] Furthermore, as best seen in FIG. 8, the suction channels 121 leading to the suction chambers or to the suction zone 122 are made of approximately the same length, so that in the suction zone 122 , identical pressure conditions exist on both sides, and an identical volume of fluid is made available. Naturally, the foregoing statements apply likewise to the situation on the sides of casing cover 3 . In this case, FIG. 7 is only an end face view of the casing 2 opposite to the casing cover, wherein the outlets of feed channel 113 or subchannel 116 and of injector device 114 or jet nozzle 117 are shown. A separate illustration of wall 118 of casing cover 3 according to the illustration of bearing flange 4 in FIG. 8 is left off for the sake of simplicity.
[0063] As further shown in FIG. 7, the feed channel 113 communicates with a pressure control pilot for returning pilot oil, namely via a special pilot oil channel 123 . Furthermore, a leakage oil channel 124 terminates in feed channel 113 , so that returned pilot oil and leakage oil mix within the feed channel 113 with the fluid coming from the tank. After leaving respectively the feed channel 113 and subchannel 116 , the there developing total quantity of fluid is supplied via the injector device 114 , or via discharge bores 126 , and via jet nozzles 117 with a high-pressure fluid, and is thereby accelerated.
[0064] Finally, it should be emphasized that the foregoing embodiment merely given by way of example describes only the teaching of the invention in greater detail, without however limiting it to the embodiment. | A rotary vane pump for delivering a fluid, having a rotary delivery device accommodated in a casing ( 2 ), a casing cover ( 3 ) arranged on one side of the casing and a bearing flange ( 4 ) on the opposite side. A suction zone ( 12 ) is formed on each of the sides, and an injector device ( 114 ) injects a pressurized fluid into the fluid as it is delivered toward each of the suction zones to thereby assure a uniform admission of the fluid into the cells of the rotary delivery device of the pump. Also a leakage path ( 13 ) for the fluid extends between the delivery zone ( 11 ) and suction zone ( 12 ). The leakage path ( 13 ) extends on the inner side ( 14 ) of the seal at least in sections parallel to the seal ( 5,6 ). | 5 |
BACKGROUND OF THE INVENTION
1. Field of Use
The present invention relates to electronic integrated circuits (ICs) and, more particularly, to circuits which employ a standard boundary scan test access port.
2. Prior Art
A standard boundary scan test architecture was approved by the American National Standards Institute and the Institute of Electrical and Electronics Engineers in 1990. This architecture provides a means by which ICs may be designed in a standard fashion such that they or their external connections, or both, may be tested using a four or five wire interface.
The device test logic which connects to this interface is known as a test access port, or TAP. Device outputs normally controlled by the functional system logic of an IC chip may be controlled via the TAP. Also, device inputs to the functional system logic may be monitored via the TAP. All TAP control and data bits are passed in serial fashion on two lines: a test data input (TDI), and the test data output (TDO). Integral to each TAP is a TAP controller having a state machine which determines the function of the device test logic. A test clock (TCK) line and a test mode select (TMS) line determine the currently active state of each state machine. The state machine has been designed such that a logic one present at the TMS input for five consecutive clocks of TCK always results in placing the state machine in a state called test logic reset. In this state, the device test logic has no effect on the IC device functional logic circuits and the device operates essentially as if the test logic were not present. An optional test reset state (TRST*) line may be included in devices where there is a need to enter the test logic reset state without waiting for five TCK clock cycles. For example, such need may arise when there are possible output driver conflicts with other devices immediately after power up.
For compliance, the standard mandates the use of several specific operating modes for all devices while others are optional. For example, one mandated mode is known as EXTEST. This mode allows interconnections between devices to be checked by setting various outputs to known states and checking the receipt of these known states at various inputs to verify continuity. Additionally, through the use of potentially conflicting output states, the receipt of proper input states can verify the absence of shorts.
Optional modes include modes which, if present, must conform to the standard, and modes which are not defined by the standard. An example of the former is known as INTEST. This mode allows device functional logic inputs to be controlled via the TAP and device functional outputs to be monitored via the TAP. The INTEST mode allows the device functional logic circuits to be checked by applying test vectors and monitoring device response via the TAP. Modes not defined by the standard are known as private modes. An example of such a mode is a mode in which the TAP controls data shifting through an internal scan chain.
A register known as the instruction register is used to select the various operating modes of the TAP controlled test logic. Input bits destined for the TAP instruction register enter the device via the same interface line used for test data bits. The value of the data or instruction bits is determined by the current state of the TAP state machine. The length of the scan chain through the device (i.e., from the TDI line to the TDO line) is, therefore, determined by the length of the currently selected register.
The standard mandates the use of a number of registers. These registers, connected in parallel between a common serial input (TDI) and common serial output (TDO), include a bypass register, a boundary scan register and a number of optional test data registers. The length of the bypass register is defined as one bit. The instruction register has a minimum length of two bits and may be expanded as a user sees fit. For example, a 16-bit or longer instruction register may be appropriate for some applications.
During normal operation, all devices of a boundary scan chain are in the same TAP state machine state at any given time. Hence, it can be seen that the overall length of the boundary scan chain can vary widely depending upon the TAP selection of instruction versus data registers. While the length of the boundary scan chain may be minimized during the shifting of data bits by selecting the bypass register in some devices, it cannot be prevented from being expanded to the cumulative length of all device instruction registers during the shifting of instruction bits. Furthermore, since all instruction registers of the boundary scan chain must be updated together, an appropriate value must be determined for and shifted into all such instruction registers, not just the one or more instruction registers of immediate interest.
The inability to select particular devices of a boundary scan chain to receive instruction register updates, therefore, results in considerable overhead. To alter the contents of only one instruction register, the present state of all other instruction registers of the chain have to be determined and the appropriate bits made to proceed and follow the bits scanned into the instruction register of interest. For example, consider a boundary scan chain of a thousand serially connected devices, each having an instruction register 16 bits in length. To alter the 16-bit instruction register of one device, 16,000 bits would have to be shifted into the boundary scan chain once instruction register shifting was established. The shifting of 15,984 bits is viewed as overhead, since such shifting merely serves to restore the current contents of the other instruction registers not being altered. The overhead exists both in terms of time needed to shift in the bits and in the means needed in their determination.
It will be appreciated that the case where overhead would be somewhat minimized by specific instruction bit configurations and relative locations on the boundary scan chain has not been considered in the above example because of the greater importance of considering a general case.
Considerable overhead can also exist in the shifting of data bits. For example, again consider the case of a thousand devices in a single boundary scan chain. Assume, by virtue of previous instruction register entries, 999 devices have selected the bypass register and one device has selected an optional data register of 100 bits, for a total scan chain length of 1099 bits. Further, assume that it is desired to examine the contents of the optional data register each time new contents are shifted into the devices. In this case, up to 1099 shifts would be required for each change of the optional 100-bit data register, resulting in an overhead of 999 bits. Since the standard mandates loading the bypass register with a logic zero at the same time the optional data register is loaded, as determined by the state machine, the shifted data cannot be retained in the bypass registers to alleviate the overhead condition.
Overhead in boundary scan operations is significant in that it decreases the number of tests that may be conducted within a reasonable amount of time and increases the amount of external hardware and associated software needed to apply those tests.
Despite the powerful capability of the architecture defined by the standard, implementation at the level of a large board or at the system level can present problems in terms of selecting boundary scan paths of manageable length during design.
Other problems also exist in determining boundary scan paths. One such problem is the case where electrical faults or shortcomings of the test interface, as with the clock line (TCK) cause erratic test operation. In this case, diagnosing and locating the fault within the test interface and its associated logic becomes more difficult as the length of the boundary scan chain increases.
Experts in the field have attempted to increase boundary scan chain manageability by creating multiple chains which are merged into a single interface grouping by means of added controller devices which have attributes similar to TAPs. One such device is the "Backplane Test Bus Link" described by D. Bhavsar in the published proceedings of the 1991 IEEE International Test Conference." Another such device is the "Addressable Shadow Port" described by L. Whetsel in the published proceedings of the 1992 IEEE International Test Conference.
These and similar such devices represent an overhead of a different kind. They have hardware overhead beyond that which is already contained in devices having TAP controllers that conform to the above mentioned standard. In certain cases, such devices and methods could be implemented as additions to devices already defined to be incorporated as part of a given design. However, whether or not such methods are implemented as dedicated devices or incorporated as part of an integrated circuit during design, they still represent an undesirable hardware overhead in the general case.
Accordingly, it is a primary object of the present invention to provide a method and means of minimizing the bit overhead of the boundary scan serial string test operations without incurring the overhead typically found in attempts to implement boundary scan in a multiplicity of strings at a board or system level.
It is a further object of the present invention to provide such method and means of minimizing bit overhead in a manner which does not conflict with present standards to the extent that devices incorporating the present invention could be used with devices previously manufactured to conform to the standard.
It is a still further object of the present invention to provide a method and apparatus for performing verification and diagnostic operations relating to the device test logic.
SUMMARY OF THE INVENTION
The above objects and advantages of the present invention are achieved in a preferred embodiment of a test access port (TAP) included in an IC device which provides electronic access to the circuits within the IC device. According to the present invention, the TAP incorporates additional logic circuits for establishing predetermined operating modes defined by a number of new boundary scan instructions. Each such instruction prevents affected IC devices from changing in either their current operating mode or scan path length between the TDI input and TDO output as a consequence of boundary scan chain instruction register or data register shifting operations. The modes remain effective until the TAP state machine enters a test logic reset state in a conventional manner which effectively disconnects the TAP from each IC device. That is, in the preferred embodiment, the mode is effective until such state is entered either through asserting an optional test reset (TRST*) line or by the repeated clocking of a test clock (TCK) line when in a test mode (i.e., a test mode select line at a logic one) wherein the number of times depends on the state machine condition at the outset.
The instructions of the present invention allow selection of either a single bit register or a direct connection to be placed in the path between a device's TDI input and TDO output. The single bit register in contrast to the above described bypass register, retains its current value at the point during data shifting that the bypass register is required to be set to zero. The single bit register of the preferred embodiment in contrast to the bypass register, remains active in the TDI to TDO path during instruction scan operations as well as data scan operations. The direct connection minimizes the overall boundary scan chain bit length and also reduces dependency on device clocking for shift operations.
The instructions further allow test logic present at device functional (i.e., non-test) pins to either retain or release control of those pins, making them useable during both test-only operations and background TAP operations running in conjunction with normal system functions.
The above objects and advantages of the present invention will be better understood from the following description when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1a and 1b show the test logic circuits of a test access port which incorporates logic circuits of the present invention.
FIG. 2 shows a typical instruction register cell which incorporates logic circuits of the present invention.
FIG. 3 shows a typical mode control cell which incorporates logic circuits of the present invention.
FIG. 4 shows an example system used in describing the operation of the present invention.
FIG. 5 shows an on-line monitoring configuration system of the present invention for continuously verifying test logic inactivity.
FIG. 6 is a diagram illustrating a scan operation carried out by the preferred embodiment of the present invention and the prior art.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows a standard test access port (TAP) which incorporates the circuits of the present invention. As shown, the test access port includes a plurality of data registers 100, 102 and 104 and a multiplexer 118, arranged as shown. The data registers correspond to a boundary scan register 100, a bypass register 102 and internal scan register 104 which connect to multiplexer 118. The TAP further includes a typical instruction register 106, an instruction decoder 108 and a controller state machine 110. The value loaded into the instruction register 106 which is then decoded by decoder 108 determines the TDI (test data in) to TDO (test data out) path selection during data shift operations. That is, the multiplexer 118, the output of which drives TDO driver 120, is controlled via lines 117 from decoder 108 in accordance with the value defined by the previously loaded instruction in conjunction with signals from TAP controller 110.
The TAP controller 110 includes a state machine and clock circuits which generate the required-control and clocking signals applied to the different registers of FIG. 1a. Additionally, TAP controller 110 provides as outputs, select and enable signals which are applied as inputs to the instruction decoder 108 and an output driver circuit 120 respectively. The controller 110 receives as inputs, an optional test reset state (TRST*) line, a test mode select (TMS) line and a test clock (TCK) line. The TCK and TMS lines determine the currently active state of the controller state machine of each IC device. The TRST* line, if present, overrides both to force a reset.
The controller state machine is designed such that a logic ONE present on the TMS line for five consecutive clocks of line TCK always results in placing the state machine in a test logic reset state. In this state, the IC device test logic has no effect on the IC device functional logic circuits and device operates as if such test logic were not present. The TRST* line may be included in IC devices where there is a need to enter the test logic reset state immediately (i.e., without having to wait up to five TCK clock cycles).
The TAP controller 110 generates the select signal on a select line during state machine states defining when the instruction register 106 is the register selected by multiplexer 118 as the path between input TDI and output TDO. The select signal causes instruction decoder 108 to apply an appropriate select code value on line 117 designating instruction register 106 as the register to be selected. The TAP controller 110 generates the enable signal during machine states defining instruction register and data register shifting operations.
For further details regarding TAP controller 110, in addition to the TAP and boundary scan operations, reference may be made to the publication entitled, "IEEE Standard Test Access Port and Boundary-Scan Architecture," published by the Institute of Electrical and Electronics Engineers, Inc., Copyright 1990.
In the preferred embodiment, boundary scan register 100 includes a shift register section and hold/storage register section. This allows register shift and update operations to be performed independently. The instruction register 106 is similarly constructed. The boundary scan register 100 normally included as part of the IC device consists of cells logically positioned for monitoring IC inputs (i.e., signals originating from without the IC device) or pins for driving inputs to the functional logic of the IC device (i.e., to have the effect of signals originating from without the IC device) and for driving external lines which connect to outputs or bidirectional connections of the IC device. By serially scanning binary values into the boundary scan register 100 via input TDI, test vectors can be applied to an IC device to which the test system is unable to make contact, except via the TAP.
Bypass register 102 is a single bit shift register which is reset at the start of data shift operations. Generally, its purpose is to minimize the path between TDI input and TDO output. This register is selected by default each time the TAP is reset unless the device includes an optional identification register. In such case, the latter register is selected at TAP reset. The optional identification register (not shown) contains 32 bits, the one nearest to the TDO output being placed in a logic one state. Thus, the resetting of bypass register 102 allows a test system to examine the TDI to TDO path of numerous serially connected IC devices and distinguish between the two types of IC devices (i.e., those with and without identification registers).
The internal scan register (SI) 104 includes a plurality of storage cells/elements of the functional logic of its respective IC device that are interconnected to form a serial string internal to the device during test so as to facilitate testing. This type of arrangement is described in U.S. Pat. No. 3,582,902 to Allen C. Hirtle, et al.
In accordance with the present invention, two transfer registers have been incorporated into the TAP structure of FIG. 1a. These are a single bit register 140 and a zero length register 150 implemented by directly connecting the TDI input via a "zero length register" line 110 as an input to multiplexer 118. The direct connection, when selected by means of an appropriate instruction, provides logical continuity of the TDI to TDO path without necessitating clocking by the TAP. The single bit register 140 in contrast to the bypass register does not get reset at the beginning of each shift operation. The register 140 is referred to herein as the C register. The zero length register 150 is referred to herein as the D register. Referring to the direct connection as a zero length register is done only for ease of explanation in describing the present invention in light of the prior art.
The C register 140 is shown in greater detail in FIG. 1b. As seen from FIG. 1b, C register 140 includes an input section and a storage section. The input section includes NAND gates 142 through 145 which receive the different clock and control signals SHIFTIR through RESET* from TAP controller 110. The storage section includes a clocked D-type flip-flop 141 whose D input terminal connects to the TDI line and whose Q output terminal connects to one of the data selection inputs (i.e., input 4) of multiplexer 118. The clock input terminal (CLK) and reset input terminal (R) connect to the outputs of NAND gates 144 and 145 respectively.
FIG. 2 illustrates a typical instruction register cell which makes up the six-bit instruction register of FIG. 1 constructed according to the present invention. The shift register section 200 of the instruction register includes a conventional multiplexer 205 and a clocked D-type bit shift register stage 200 connected in series as shown. The instruction register hold section of the cell consists of a D-type clocked instruction bit register stage 252. The instruction register stage 252 and part of its directly associated circuitry has been modified to include a multiplexer 250 positioned between the instruction bit shift register cell 206 and instruction register bit cell 252. Normally, the D-input of stage 252 connects to the output of stage 206 via an extension of the Q output line which connects to TDO through further logic. According to the present invention, logic elements 250 and 254 have been included and means are provided to recirculate stage 252 via an extension of the Q line 256. The AND logic gate element 254 allows decoding of four instruction register bit signals, applied via lines A through D (hereinafter bits A through D). The other bit storage elements of the instruction register of the present embodiment are not shown since they are not utilized by the preferred embodiment of the present invention. Thus, the logic elements 250 and 254 recirculate instruction register values for four instructions which are determined by bits A through D and not the other two bits. The recirculation of instruction values is an important part of the present invention.
As previously mentioned, FIG. 2 shows only stage one of the six-bit instruction register 106 of the present embodiment. As shown, logic element 254 is connected to receive signals corresponding to instruction register bits A through D for decoding four instructions. Each of the remaining cells contains identical logic circuits (i.e., basic instruction register cell) and also utilize the output of logic gate 254 and an element similar to multiplexer 250.
FIG. 3 shows an alternate embodiment of the present invention. This embodiment allows for direct control of various operating modes of the TAP test logic as opposed to decoding values contained in the instruction register 160. The outputs of this circuitry provides operating mode signals which can be used for controlling the selection of test versus functional logic, selecting the boundary scan register input, disabling of all output drivers, etc.
FIG. 3 shows two such cells, one which provides mode bit A representative of a standard function and a second cell which provides a transfer mode bit. As seen from FIG. 3, each register stage of shift register section 200 is identical to section 200 of FIG. 2. However, mode bit A corresponds to the output of cell stage 310. An AND logic gate element 308 provides the decoding necessary to set or reset cell 310 at the rising edge of the clock line UPDATEIR. If the transfer mode bit signal on line 312 is a logic zero, the decoded value of the instruction corresponding to shift bits A' through F' is transferred to the D-input of mode bit A cell stage 310 by a multiplexer 306. Alternatively, if the transfer mode bit signal is a logic one, multiplexer 306 causes recirculation of cell stage 310, retaining the stored value of mode bit A.
Each set of elements 201, 202 and 203, 204 perform a function similar to the function of elements 200 and 206 in FIG. 2 and are not part of a single instruction register shift string. That is, they pre-decode certain bits to effect operating modes versus having to decode the value subsequently loaded into the instruction register in the embodiment of FIG. 2.
DESCRIPTION OF OPERATION
With reference to FIGS. 1 through 6, the operation of the present invention will now be described. The apparatus of the preferred embodiment of the present invention incorporates four specific instructions. These are designated as CTRANS, CTRANT, DTRANS and DTRANT. The first letter of each designation represents the register of the present invention chosen in the TRANsfer path between the TDI input and the TDO output. The prefix letter C of the designation represents the clocked path of the single bit register while the prefix letter D represents the direct or zero length register. The last letter of each designation represents the overall operating mode of the system which connects to the test system wherein the letter S represents the system or functional mode in which the system is performing its normal use task (i.e., the test logic is essentially transparent) and the letter T represents the test mode in which various IC system functions are being interrupted for test purposes.
The CTRANS instruction is carried out by loading a predetermined value into the instruction register. Referring to FIG. 2, it is seen that the element 252, D flip-flop, corresponds to bit A of the instruction register. The other bits of the instruction register are B through F. The loading of any instruction depends on the current instruction not being one of the four TRAN instructions. In the present embodiment, a TRAN instruction is assumed to have the bit configuration 0111XX, where the first bit is bit A, second bit is B, etc., and the values of bits E and F are irrelevant (X). It should be noted that, in the absence of a TRAN instruction in the instruction register, AND gate 254 produces a logic zero output on line 253, resulting in establishing a transfer path between lines 251 and 255 through multiplexer 250. If the current instruction is a TRAN instruction, the transfer path caused by a logic one on line 253 is established between lines 255 and 256 which causes the current instruction to be reloaded/retained.
Under control of the TAP controller 110, the bit configuration for the CTRANS instruction is shifted into the six instruction shift cells, storage element 206 being one such cell. Data from the TDI input arrives at the D-input of storage element 206 by virtue of the path selected by the TAP controller SHIFTER line input to multiplexer 205. When all instruction bits for the six bits of the present instruction register, and all bits of all instruction registers of the various boundary scan devices on the serial string of which the present IC device is a part have been shifted in, the TAP controller within each such device causes the UPDATEIR line to change from a logic zero to one. The resulting rising edge at storage element 252 and its numerous counterparts on the present and other devices causes the binary value of element 206 to be transferred to element 252 through multiplexer 250 in the manner described previously.
Referring now to FIGS. 1a and 1b, the TDI to TDO path selected by the instruction register 106 and TAP controller state machine is established to be through storage element 141 by virtue of instruction decoder 108 which connects to multiplexer 118. Each TRAN instruction, upon being decoded by instruction decoder 108, disables the select input from TAP controller 110, preventing the logic which causes the instruction register path to supersede whatever other path is selected prior to the instruction scan series of state machine states.
The data arriving at input TDI is shifted through to the TDO output at each clocking of element 141. The clocking is produced by the TAP controller 110 which results in signals on the SHIFTIR and CLOCKIR lines applied to NAND gate element 142 and signals on the SHIFTDR and CLOCKDR lines applied to NAND gate element 143. It is important to note that, once a TRAN instruction becomes the current instruction of the TAP, the instruction bits and data bits are treated alike by the IC device insofar as their TDI to TDO path is concerned.
The CTRANS instruction further allows the system logic of the device to control the device system functional outputs. This is accomplished by virtue of mode bits as shown in FIG. 3. As discussed, mode bits differ from instruction bits in that they are predecoded. That is, unless bit configurations are chosen only to allow hardware simplicity, instruction register bits are required to be processed by a decoder (e.g. decoder 108) to produce the various modal signals necessary to control device operation. In the case of mode bits, the decoded results are clocked into the mode register stages (e.g. elements 302 and 310 of FIG. 3) at the time instruction register bits would otherwise be clocked into the instruction register. It is possible for both types of register embodiments to exist either exclusively or simultaneously in a given system. The mode outputs activated by the CTRANS instruction can be used to activate mode selections logic, not shown.
The CTRANT instruction differs from the CTRANS instruction in that mode selection logic activates TAP control of the device system functional outputs. The IC device is, therefore, in a test mode. The mode selection logic activated by the CTRANT instruction is not shown.
It is important to note that certain boundary scan operations can be conducted without affecting system functional operation. Thus, the presence of a TRANT (CTRANT or DTRANT) instruction does not necessarily mean that system functionality has been interrupted.
The DTRANS instruction operates as does the CTRANS instruction except that zero register line 150 is selected as the input to multiplexer 118 by lines 117 on FIG. 1a.
The DTRANT instruction operates as does the CTRANT instruction except that zero register line 150 is selected as the input to multiplexer 118 by linen 117 on FIG. 1a.
Four instructions have been described: DTRANS, DTRANT, CTRANS and CTRANT, the distinctions being in the TDI to TDO path selected (C register versus D register) and overall K device operation (system functional versus test). It will be appreciated that other types of instructions may be provided. For example, the current operating mode of the device could be retained through use of the such instructions by additional instructions which could be designated as CTRANC and DTRANC, where the letter "C" indicates "current" mode. Also, the test mode which results from the execution of a CTRANT or DTRANT instruction could be used to specify retaining the current test mode or force other user predetermined test modes. Such additional instructions might be designated as CTRANT1, CTRANT2, where T1, T2 indicate test mode 1, test mode 2, etc.
The various modal possibilities can be readily determined by referring to the various standard logic implementation found in the above referenced publication entitled, "IEEE Standard Test Access Port and Boundary-Scan Architecture."
Referring to FIG. 2, the reset input of instruction register bit stage 252 is controlled by the output of logic NAND element 145 of FIG. 1b on line 146. Thus, whenever line TRST* or line RESET* is in a logic zero state, stage 252, and all other instruction register bit stages of the IC device are reset. The TRST* line reflects the state of the optional fifth TAP interface TRST* signal, which becomes a logic zero only when it is desired to reset the IC devices to the test logic reset TAP state by a tester. The TRST* line is not included in IC devices where the optional fifth line is not installed. The RESET* line becomes a logic zero when TMS line is held low through repeated clocking of line TCK. The TAP controller state machine has been designed such that this occurs within five TCK cycles. When either the TRST* line or RESET, line becomes a logic zero, then the instruction register 106 is reset. At that point, a TRAN instruction can no longer be the current instruction and instruction loading is no longer blocked. Thus, TRAN instructions operate to lock the IC device in a given TAP condition until the test interface controller (tester) causes the state of all TAP state machines in a given string (i.e., those having the same TMS and TCK or TRST* inputs) to assume a test logic reset state.
FIG. 5 shows how the present invention is able to verify the absence of impending test operations using the DTRANS instruction. This capability is intended for use in situations when unexpected control of device operation could be catastrophic. An example is an aileron control system of a jet fighter where the tester could accidentally force the execution of a maneuver exceeding the structural limitations of the aircraft. In some situations, it might be determined that sufficient safeguards are already built into a standard boundary scan system in that the test controller can be directed to hold TRST* at a logic zero and TMS at a logic one while clocking TCK indefinitely so as to produce the test logic reset state at all state machines. In other situations, such as those to which this operating mode is directed, the ability to provide independent verification that test operations are not impending at any point in the boundary scan chain is considered important.
Referring to FIG. 5, there is shown a test controller 500 which is a normal boundary scan test system. System 510, the functional unit, has been constructed of devices in which the DTRANS instruction can be executed. Generator 520 is an asynchronously operating oscillator. A verifier 530 compares the signal received on line 521 with that received on line 511. A switch 540 allows the generator signal on line 521 to be the input to the TDI input of system 530 in lieu of the TDO input on line 503.
Assuming successful system checkout by the test controller and normal functional operation of the system is about to commence, the test controller is directed to cause a DTRANS instruction to be executed in each device of the boundary scan chain, followed by holding line TMS at a logic zero when the state machine is in the run test idle state or by suspending TCK clocking. At this point, any input to the system TDI input is allowed to ripple through the scan path, now composed exclusively of a series of D registers, and appears at the TDO output after an appropriate delay. Since the DTRANS instruction can only be suspended when the test logic reset state occurs in a TAP device and since no device without an internal fault can be made to change instructions without first attaining the test logic reset state, the continued presence of essentially a direct path can be used as verification that no undesirable device activity is about to take place.
After executing the DTRANS instruction, switch 540 is then thrown to the position connecting lines 512 and 521. The verifier 530 now is able to compare the signals received on lines 521 and 511. After adjusting for the scan path delay, a decision can be made as to whether there has been an interruption of the scan path. Sensing such an interruption can be used to indicate an unplanned activity allowing backup equipment to be automatically invoked so as to prevent possible misoperation of system 510 from causing further problems.
Referring to FIGS. 4 and 6, operation of the present invention will now be described in terms of savings of the number of bits needed to be passed through the serial chain in order to test a given device on the serial chain.
Tester 400 is connected to a printed wire board assembly 430 by means of the standard four-wire boundary scan interface which includes lines TMS, TCK, TDO and TDI. Board 430 is populated with 100 integrated circuits, IC1 through IC100 of which the first device 410 and last device 420 are shown. The tester 400 connects directly to the TMS and TCK input of each IC device via lines 401 and 402, respectively. For purposes of simplicity, the drive circuits which may normally be required have been omitted. The tester TDO line 403 connects to TDI input of the first device IC1 in the serial string, IC1. Similarly, line TDO 411 of IC1 connects to TDI input of the next IC device (not shown) in the serial string. The TDI input line 412 of the last IC device IC100 of the serial string is driven by the TDO output of the penultimate device (not shown). Line 421 completes the serial string by connecting the TDO output of the last device IC100 of the serial string back to the TDI input of the tester 400.
For illustrative purposes, all devices are assumed to have six test registers: an 11-bit instruction register, a 1-bit bypass register, a 1-bit C-register, a 0-bit D-register, a 43-bit boundary scan register (labeled BS) and a 130-bit internal scan register (labeled SI). For illustrative purposes, the lengths of the instruction, boundary scan and internal scan registers within the IC devices have been arbitrarily chosen at 11, 43 and 130 bits, respectively. In this example, except for having the same register lengths, the 100 ICs differ significantly in function from one another. That is, there is no relationship between the optional codes needed to be supplied to the various instruction registers, the bit positions versus device pin functions of the various boundary scan registers, the internal device functions of the various internal scan registers and the functional logic contained within the various IC devices. It will be presumed that a sufficient internal test of each IC device may be conducted by applying 1,000 test vectors to each device. That is, each IC device is tested by shifting in stimulus to each IC device from the tester 400, clocking the IC device, and shifting the results out to tester 400 for evaluation after each test vector.
In the preferred embodiment of the present invention, during Scan 1, all IC devices are issued an instruction to select the boundary scan register (BS) so as to establish it as the path between TDI and TDO in Scan 2. This requires the tester 400 to shift or scan 1,100 bits into the serial chain of the IC devices in addition to applying signals to lines TMS and TCK such that the TAP controller state machine in each IC device causes the appropriate shifting therein. During Scan 2, the boundary scan register of each IC device is then loaded. This, requires 43 bits for each device, or a total of 4300 bits. At this point, the various IC devices comprising board 430 can be in a state suitable for testing. That is, with proper selection of the values loaded into the various boundary scan registers, conflicts between the various devices that may otherwise take place during subsequent test operations may be eliminated. For example, if the relevant outputs of all IC devices driving a bus were set to a high impedance state, drive conflicts between IC devices on the bus would be minimized as a concern during testing.
The two scans described above are diagrammed in FIG. 6. In FIG. 6, the scan operations to perform a one thousand vector test of one IC device in a scan string of 100 IC devices is shown on the left for a group of IC devices with TAPs constructed according to the present invention and on the right for the prior art. The scan steps and their functions are noted in the center of FIG. 6. The number of bits scanned in each step is tabulated at the left for the present invention and at the right for the prior art. For illustration, IC40 has been chosen as the IC device to be tested by the test vectors. In either the case of the present invention or the prior art, the first two scan steps are the same, each requiring 1,100 bits and 4,300 bits, respectively, to be scanned. In Scan 1, an instruction register scan is performed on the entire string of 100 IC devices. The instruction for each IC device specifies the boundary scan register is to be scanned during the next data register scan. The "11 (BS)" in each block of FIG. 6 relating to Scan 1 indicates the length of the register being scanned and, for instruction register (IR) scans, the type of instruction. In Scan 2, a data register (DR) scan, the boundary scan (BS) registers are loaded, each with 43 bits for a total of 4,300 bits for the 100 IC devices of board 430.
In Scan 3, the first departure takes place between the present invention and prior art. Both are IR scans. In the case of the present invention, a DTRANT instruction is issued to each IC device other than IC40 (i.e., to the 99 others), which is issued an instruction selecting the boundary scan register. In the prior art, an instruction to select the bypass register would have been issued to each of the 99 other IC devices and to the boundary scan register of IC40. In FIG. 6, the selection of the D register is indicated in parenthesis as "D" and the bypass register as "BY". In both implementations, Scan 3 requires 1,100 bits to be scanned.
In Scan 4, a DR scan, the first example of the bit economy aspect of the present invention is illustrated. In Scan 4, the boundary scan register of IC40 is to be loaded with 43 bits. In the case of the present invention, the output state of the tester 400 is applied to TDO which is in turn directly transferred to the TDI input of IC40. That is, since the previous instruction (Scan 3) selected the zero-length D register as the path between TDI and TDO of each IC device other than IC40, the level present at the TDI input of IC40 will be the same as the level present at the TDI input of IC1. Again, because of the D register selection, the level present at the TDO output of IC100 will be the same as the level present at the TDO output of IC40. Aside from the TDI to TDO delay within each of the other ICs, the tester TDO output is essentially directly connected to the TDI input of IC40 and the TDO output of IC40 is essentially directly connected to the TDI input of the tester. Given this essentially direct connection, the 43 bits for the boundary scan register of IC40 are loaded by a 43-bit scan operation. Alternatively, in the prior art case, the single bit bypass (BY) register has been selected as the path between TDI and TDO for each IC other than IC40. Therefore, after the tester has scanned the 43 bits intended for IC40 into the TDI input of IC1, 39 more bits must be scanned in so that the first 43 bits will be transferred to IC40. At the end of the scan operation, 39 bits will be present in the bypass (BY) registers of devices IC1 through IC39. The bits present in bypass (BY) registers at the end of a scan operation have no effect on operation of the test logic. That is, standard boundary scan operations define the boundary scan register being set to zero at the beginning of each scan operation. The 39 extra bits needed to be scanned in the prior art case result in a total of 82 bits for Scan 3, versus 43 bits in the case of the present invention.
In Scan 5, an IR scan, the difference is more dramatic. The purpose of this scan is to select the 130-bit internal scan register of IC40, denoted by "(SI)" in FIG. 6, for subsequent data register (DR) scans. In the case of the present invention, by virtue of the essentially direct connection previously established with the tester, the scan will consist of 11 bits. In the prior art case, the scan string consists of the instruction registers of all 100 IC devices, since the TAP controller state machines of all such IC devices must be in the same state. Thus, the scan string in the prior art case will be 1,100 bits. Furthermore, since unspecified IC operation can result from allowing instruction registers to be loaded with residual values, it is generally considered good practice to load all instruction registers with known values. Therefore, the prior art case requires 1,100 bits to be scanned in Scan 5, versus 11 in the case of the present invention.
In Scan 6, a DR scan is used to load the 130-bit internal scan register of IC40 and 130 bits are scanned in the case of the present invention. In the prior art case, an extra 39 bits would be required as in the loading of the boundary scan register in Scan 4.
Scans 7 through 11 are repeated 999 times in order to achieve the one thousand vector test intended to be conducted on IC40 as discussed previously.
In Scan 7, an instruction is to be loaded which applies a clock cycle to the functional logic within IC40. That is, data for a single test vector was loaded in Scans 4 and 6. The results of the test will replace that data when a clock pulse is applied. The clock pulse will be generated internally within IC40 as a result of the appropriate instruction having been loaded into the instruction register. The practice and methods of constructing an IC device so as to operate for test purposes in this fashion are well known in the art. As in Scan 5, 11 bits will be scanned in Scan 7 in the case of the present invention as opposed to 1,100 bits in the prior art case. Since Scan 7 is repeated 999 times, the number of bits scanned in each case will therefore be 10,989 versus 1,098,900, respectively.
In Scan 8, another IR scan, the boundary scan register of IC40 will be selected for subsequent scanning. As in Scan 5, the bypass (BY) registers of the other IC devices will be selected in the prior art case. As explained in Scan 7, the number of bits scanned in the case of the present invention would be 10,989, versus 1,098,900 in the prior art case.
Scan 9, a DR scan, serves the dual purpose of scanning out the results of the previous test vector as described in Scan 7 and loading a new test vector to be applied later. In the case of the present invention, this is accomplished by scanning in 43 bits. In the prior art case, 103 bits will have to be scanned. That is, the IC40 boundary scan register bit closest to the TDI input of IC40 is the 103rd bit position from the TDO output of IC100 in the prior art case. Scanning the full 142 bits of the 43-bit boundary scan (BS) register of IC40 plus the 99 bits of the bypass (BY) registers of the other IC devices is avoided by beginning to scan new test vector data before the previous test vector results have fully emerged from the TDO output of IC100 (again, only applicable to the prior art case). In the 999 executions of Scan 9, 42,957 bits would be scanned in the case of the present invention versus 102,897 bits in the prior art case.
Scan 10, an IR scan, is the same as Scan 8, except that the internal scan (IS) register of IC40 will be selected on subsequent DR scans as opposed to the selection of boundary scan register. The number of bits scanned will be the same in both cases.
Scan 11, a DR scan, is similar to Scan 9, except that the 130-bit internal scan register is used instead of the 43-bit boundary scan register. In the case of the present invention, 130 bits would be scanned in each of the 999 executions of Scan 11 for a total of 129,870 bits. In the prior art case, 190 bits would have to be scanned each time, for a total of 189,810 bits.
Scan 12 is the same as Scan 7, but is executed only once. Similarly, Scan 13 is the same as Scan 8, but is executed only once. For each of these two scans, 11 bits would be scanned in the case of the present invention versus 1,100 bits in the prior art case.
Scan 14 is the same as Scan 9, but is executed only once. Furthermore, since no new test vector is to be loaded, the levels applied at the TDI input of device IC1 during the scan are irrelevant. Scanning 43 bits is required in the case of the present invention versus 103 in the prior art case.
Scan 15 is the same as Scan 10, but is executed only once. In the case of the present invention, 11 bits would be scanned, versus 1,100 for the prior art case.
Scan 16 is the same as Scan 11, but is executed only once. Furthermore, since no new test vector is to be loaded, the levels applied at TDI of IC1 during the scan are irrelevant. Scanning 130 bits is required in the case of the present invention versus 190 in the prior art case.
As shown in FIG. 6, the total number of bits needing to be scanned to test device IC40 in the manner described is 212,684 bits in the case of the present invention, versus 3,600,851 bits in the prior art case.
In certain situations, achieving bit economy using the C register in lieu of the D register may be preferred. As the number of devices in the scan path increases, so does the cumulative delay through the path. That is, a certain delay exists between a TDI input pin of a given device and its TDO output when the D register is selected as the TDI to TDO path. The cumulative delay affects the rate at which bits may be clocked through the scan path. That rate affects the overall test time. When the number of devices in the scan chain would diminish the test rate to an extent considered significant, by using D registers, C registers may alternatively be utilized.
Since C registers introduce no cumulative delay in the scan path, but operate as do the other registers of the TAP, clock rate is not diminished. Since C registers, unlike bypass registers, are not reset at each scan and are able to transfer both data and instruction bits, C registers in the scan path before and after the IC device of immediate interest effectively comprise a pipeline to and from that device. As is the case with other such pipelines, the difference in time between the loading of bits and their eventual effect (e.g. positioning within the pipeline) requires management overhead.
Selective use of D registers may also be used in diagnosing clocking problems affecting proper operation of the scan chain. Referring again to the example of IC40 in FIGS. 4 and 6, and assuming the TCK clock line observed at IC40 was affected by noise within the system, that fault might be diagnosed by attempting to perform the testing of each IC device in turn after issuing a DTRANT instruction to all other IC devices. In the case of certain faults, device IC40 would be the only device unable to consistently pass a sequence of test operations. In the case of the prior art, scan path misoperations would be more likely to render impracticable the diagnosis through TAP operations (i.e., without manual probing).
The functionality of the D register could be further extended to provide for interrupt signalling in addition to verification. For example, a multi-input gate could be added to the single wire D register path. One input of the gate could be connected to the TDI input, and the other input connected to be normally at a logic one level. The output of the gate would be connected like the D register connects to the multiplexer 118. Thus, when the system is used in a verification mode such as that depicted in FIG. 5, a change in the level of the normal logic one level at the gate input in any of the IC devices included in the serial scan chain would be apparent at the TDO output of the final device in the serial scan chain (i.e., at the verifier input). The change in level could be made to occur when a particular IC device detected a fault condition or any other significant event. Thus, an interrupt mechanism is provided wherein any event sensed by the circuitry within an IC device connected in the serial scan chain will be propagated through the serial scan chain to other circuitry (internal or external).
It will be appreciated by those skilled in the art that many changes may be made to the preferred embodiment of the present invention without departing from its teachings. For example, the invention is not limited to any specific boundary scan architecture or specific instruction coding.
While in accordance with the provisions and statutes there has been illustrated and described the best form of the invention, certain changes may be made without departing from the spirit of the invention as set forth in the appended claims and that in some cases, certain features of the invention may be used to advantage without a corresponding use of other features. | A method and apparatus provides improved modes of operation of a standard test bus based on a standard boundary scan architecture which minimizes the number of bits required to be serially scanned into the controllers of the various devices connected to the bus by temporarily disabling scan paths not required to be utilized. Means for continuously verifying the inoperative state of test logic and for diagnosing test logic faults are also described. | 6 |
CROSS REFERENCE TO RELATED APPLICATIONS
The present application is a continuation application and claims priority benefit under 35 USC §120 to PCT/EP2013/003042, filed on Oct. 10, 2013, which is a PCT application of and claims priority benefit to German Patent Application No. 10 2012 220 620.5 filed on Nov. 13, 2012, the entireties of each of which are incorporated by reference herein.
FIELD
The invention relates to a method for processing audio signals for a therapy of subjective tinnitus with an individual tinnitus frequency. The invention also relates to a computer program.
BACKGROUND
The perception of sounds without the existence of an internal or external sound source is called subjective tinnitus. A tinnitus is an often chronic illness and generally occurs with a constant individual tinnitus frequency. The physiological cause for this is usually an abnormal neuronal activity in the primary auditory cortex.
A possible therapy for relieving a subjective tinnitus is based on the approach of reducing the abnormal neuronal activity in the auditory cortex using lateral inhibition and thereby initiating therapeutically effective normalization of this neuronal activity based on neuronal plasticity.
Lateral inhibition is thereby in particular a characteristic circuitry of the nerve cells in the central nerve system, which causes certain nerve cells to be stimulated in a peripheral stimulus and the activity of different nerve cells is inhibited for the perception of comparable stimuli.
The therapy correspondingly consists of listening to sounds or music, in which the frequency portions were filtered out in the range of the tinnitus frequency. For example, white noise is used for this, from which therapeutic data can be generated for any tinnitus frequencies because white noise has a very broad and even frequency spectrum. White noise is however considered bothersome and unpleasant by the patient in the long run. Willingness to use the therapy regularly and permanently is thereby reduced.
Music is more pleasant to listen to, whereby up until now only professionally produced music with a particularly high audio quality was considered suitable. Since moreover an individual processing for each individual patient is required, a patient generally only has a few different music pieces available for the therapy. These often do not meet the personal tastes of the patient.
SUMMARY
Based on this state of the art, the object of the present invention is to improve the availability of audio data suitable for tinnitus therapy and to enable in particular tinnitus therapy based on audio data selected based on personal tastes.
This object is solved through a method for processing audio signals, in particular for therapy of subject tinnitus with an individual tinnitus frequency, comprising the following method steps:
provision of a first audio signal, determination of a blocking range in the frequency spectrum of the first audio signal with a predefinable frequency width on the basis of a predefinable therapy frequency, creation of a second audio signal from the first audio signal using a filter for a portion of the signal in the first audio signal in the blocking range, determination of an auditory energy of the first audio signal or of the second audio signal within at least one predefined or predefinable therapeutically applicable frequency range specification of an evaluation parameter for the second audio signal as a function of the auditory energy and of a frequency separation between the therapeutically applicable frequency range and the blocking range.
One advantage of the invention is that generally all audio signals come into question as the first audio signal, wherein an objective scale is made available by means of the evaluation parameter, to which extent the second audio signal is suitable for therapy of tinnitus with the individual tinnitus frequency of the present individual case. The second audio signal is then preferably only released or used for tinnitus therapy if the evaluation parameter lies above a predefinable evaluation parameter.
The evaluation parameter is suitably designed in particular to specify how strong the activity of the tonotopic neutrons to the therapy frequency or respectively to the blocking range is inhibited by lateral inhibition based on the stimulation of tonotopic neurons to the therapeutically applicable frequency range when listening to the second audio signal. For this, for example knowledge and models of the functionality of the human ear, in particular the lateral inhibition between the neurons of the primary auditory cortex are taken into consideration.
The evaluation parameter is thus in particular an objective scale for how strong the abnormal activity of the neurons causing the tinnitus is inhibited when hearing the second audio signal. Since this is the goal of the tinnitus therapy, the respective evaluation parameter can be determined for example for existing audio signals, which have proven empirically to be suitable or unsuitable in tinnitus therapy, and are specified by comparison with the evaluation parameter determined for the second audio signal, inasmuch as the second audio signal is suitable for the tinnitus therapy.
Another advantage of the invention is that targeted therapeutic control is enabled based on the evaluation parameter. For example, the treating doctor can specify, taking into account the evaluation parameter, how often or how long the second audio signal should be heard for optimal therapeutic success.
The filter used according to the invention is in particular a band-stop filter, through which a portion of the signal of the first audio signal with frequencies in the blocking range is completely or partially removed during creation of the second audio signal. The effect of the band-pass filter should thereby be mainly restricted to the blocking range so that in particular the first audio signal and the second audio signal outside the blocking range mainly match.
The therapeutically applicable frequency range is predefined in particular such that there is no overlap with the blocking range. The auditory energy of the first audio signal within the therapeutically applicable frequency range thus does not mainly differ from that of the second audio signal.
Auditory energy is in particular the sound energy of an audio signal totaled or integrated over all frequencies of a frequency range or of a frequency interval. A frequency range or frequency interval can also be a bandwidth. The auditory energy within a frequency range thus correlates with the strength of a stimulation of the tonotopic neurons at this frequency range.
The method according to the invention is preferably characterized in that the first audio signal and/or the second audio signal is respectively a digital audio signal, in particular a digital audio file or a digital audio data flow.
A digital audio file is in particular a saved digital audio signal, which can be accessed repeatedly and with chronological asynchronism. In contrast, an audio data flow is in particular an audio signal, which is available once and/or with chronological synchronism or in real time.
The first audio signal is preferably normalized before the creation of the second audio signal. The signal-to-noise ratio of the second audio signal is hereby improved and in particular noise effects, which occur during the creation of the second audio signal, in particular during use of the filter, are reduced.
Within the framework of the invention, normalization or controlling is understood in that the first audio signal is scaled such that the highest signal value within the first audio signal corresponds with a predefined maximum value and/or the lowest signal value within the first audio signal corresponds with a predefined minimum value. In the case of digital signals, the maximum value and the minimum value are for example determined by the quantification word width of the first audio signal.
Quantification word width is in particular, in a digital audio signal, the size or word length of the digital information for the coding of a single pulse height value. For example, in a quantification word width of 16 bits, 65536 different discrete values are available for the coding of the pulse height of the audio signal.
It is preferably provided as a further method step that the first audio signal and/or the second audio signal is corrected to compensate for frequency-dependent elevations and/or dampings by a playback device with a non-linear frequency path.
The first audio signal is preferably corrected before or during the creation of the second audio signal. The correction can also be performed during or with the second audio signal.
In this connection, correcting means in particular that frequencies, which are damped due to a non-linear frequency path of the playback device, are correspondingly increased in the audio signal and frequencies, which are increased due to the playback device, are correspondingly damped in the audio signal.
A playback device is in particular a loudspeaker, headphones or a portable or nonportable playback device, for example a stereo system or an mp3 player.
The correcting of the first audio signal ( 10 ) or respectively of the second audio signal ( 12 ) preferably takes place by means of a filter ( 121 , 120 ).
The filter coefficients needed for this originate for example from a database, in which filter coefficients for different known playback devices, for example a plurality of procurable headphone models, are stored or saved for repeated use.
A filter used in a method according to the invention is preferably a filter with a finite impulse response. Such filters are also called FIR filters (Finite Impulse Response) or transversal filters. A filter with a finite impulse response can be advantageously implemented as a digital filter and is stable by design. In particular, unwanted oscillations initiated by the filter are thus excluded.
The therapeutically applicable frequency range is preferably analyzed subdivided into frequency intervals, wherein in particular respectively an auditory energy of the first audio signal or of the second audio signal is determined within each frequency interval and the evaluation parameter is determined depending on the respective auditory energy and of a respective frequency distance between the blocking range and the respective frequency interval taking all frequency intervals into consideration. It can thereby be taken into consideration that the lateral inhibition generally decreases with an increasing frequency distance, whereby the correlation between the evaluation parameter and the actual inhibition of neuronal activity is increased. The effort for the analysis in contrast to an analysis of the continuous frequency spectrum is simultaneously considerably reduced through the use of frequency intervals.
The frequency intervals are thereby preferably selected depending on human hearing and have respectively for example a frequency width of ⅓ bark or ⅓ ERB. These two scales are respectively linked non-linearly with the frequency and consider the logarithmic frequency behavior of human hearing over broad ranges.
Furthermore, the first audio signal or respectively the second audio signal is preferably analyzed subdivided into temporally consecutive sections for determining the evaluation parameter, wherein in particular each section comprises a predefinable duration or a predefinable number of digital audio samples. Within the framework of the invention, consecutive sections can be spaced, overlapping or adjacent sections. It is hereby achieved that the evaluation parameter is determined in a time-dependent manner with a temporal resolution, which depends in particular on the duration of a section. In the case of a sampling rate of 44.1 kHz, a section is for example 576 audio samples, whereby a good compromise is achieved between frequency resolution and temporal resolution. The length of the sections can also be designed variably in order to obtain both sections with a high temporal resolution and also sections with a high frequency resolution.
An audio sample is in particular the pulse height information of a digital audio signal at a point in time. The sampling rate or sampling rate thereby specifies in particular the temporal digitalization or discretization of the audio signal, i.e. how many audio samples are coded per time unit in the digital audio signal.
If the first audio signal or respectively the second audio signal has at least two channels, each channel is preferably analyzed individually for determining the evaluation parameter. Phase shifts between the two channels and the corresponding effects on the lateral inhibition of neurons in the auditory cortex can thereby be considered in the determination or calculation of the evaluation parameter.
Alternatively, the evaluation parameter can be determined based on an individual channel or from a mixed signal of several channels. This is in particular advantageous when analysis effort is time-critical, for example in real-time applications of the method according to the invention.
A method according to the invention is particularly preferably executed using a data processing device.
The data processing device is designed in particular for the digital processing of analog and/or digital audio signals, wherein analog audio signals are digitized for example by means of data processing device before executing the method according to the invention.
A suitable data processing device is for example a server, a multimedia computer or a laptop, which have the advantage of being accessible to anyone.
Preferably, the data processing device is or will be connected with a playback device by means of a first data connection, wherein the second audio signal is transferred by the data processing device to the playback device via the first data section.
A playback device is in particular designed to play back audio signals and is for example a computer or laptop, a smartphone or a mobile playback device.
Suitable data connections are for example provided via a network, like Ethernet, LAN (Local Area Network) or WLAN (Wireless Local Area Network), via standard interfaces like Bluetooth, USB (Universal Serial Bus) or infrared or as telecommunications connection like ISDN, DSL, GSM or UMTS.
Preferably, the data processing device is or will be connected with a data storage device by means of a second data connection, wherein the first audio signal is transferred by the data storage device to the data processing device via the second data section.
The invention also expressly comprises such embodiments, in which the playback device is designed as a data storage device. In this case, the first data connection and the second data connection can be produced in particular identically or produced in succession temporally.
The first data connection and/or the second data connection is or will be or respectively are or will be preferably produced via a data network, in particular via the Internet.
Regardless of the format of the first audio signal, the second audio signal is for example an audio file, which is made available for access or download via the data network. The second audio signal can also be an audio data flow, which is transferred to the playback device in real time via the data network.
The object underlying the invention is further solved by a computer program product with program code means, which are designed to execute a method according to the invention when the program code means is executed on a data processing device.
The program code means are preferably saved on a data storage medium readable by a computer. This can hereby be a CD, a disk, a hard drive or even storage space on a server. The saving can be provided both in a RAM or ROM or a solid-state memory or fixed-disk memory on a server.
Within the framework of the invention, in particular also program code means, which are saved on an Internet server and offered as download for the temporary or permanent saving, installation and/or use on a computer or laptop, are understood as computer program products.
The object based on the invention is also solved by a computer system with a data processing device, which is set up to execute the method according to the invention.
For this, the computer system comprises for example program code means, which are designed to execute a method according to the invention when the program code means are executed on the data processing device. Alternatively or supplementary, the data processing device has suitable components, for example electronic circuits or microelectronic components, for executing individual or all method steps.
Further characteristics of the invention will become apparent from the description of embodiments according to the invention together with the claims and the included drawings. Embodiments according to the invention can fulfill individual characteristics or a combination of several characteristics.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is described below, without restricting the general idea of the invention, using exemplary embodiments with reference to the drawings, whereby we expressly refer to the drawings with regard to all details according to the invention that are not explained in greater detail in the text. The figures show in:
FIG. 1 is schematically an exemplary implementation of a method according to the invention,
FIG. 2 is schematically the amplitude frequency response of a used filter according to the invention,
FIG. 3 is schematically a flow chart of a filter of a method according to the invention,
FIG. 4 is schematically a flow chart of a signal analysis of a method according to the invention,
FIG. 5 is schematically a further exemplary implementation of the method according to the invention,
FIG. 6 is schematically another exemplary implementation of the method according to the invention,
FIG. 7 a is schematically a section of a flow chart of a filter of a method according to the invention and
FIG. 7 b is schematically a section of a flow chart of a method according to the invention.
In the drawings, the same or similar types of elements and/or parts are provided with the same reference numbers so that a re-introduction is omitted.
DETAILED DESCRIPTION
An exemplary implementation of the method according to the invention is shown in FIG. 1 . A server 40 is thereby provided, which is accessible for example via a corresponding web front end via the Internet 42 by a client computer 44 .
Via the client computer 44 , an original audio signal 10 , for example an audio file saved on the client computer 44 , is transferred to the server 40 via the Internet 42 , where a therapy signal 12 is created by means of a digital filter 120 . For the configuration of the filter, an individual tinnitus frequency 20 or therapy frequency 20 and optionally a blocking range 22 , in particular blocking range width, are provided via the client computer 44 , which have been determined for example by the treating doctor for the individual tinnitus patient. If no blocking range 22 is specified, a standard value, for example an octave, is used for the blocking range 22 .
In a signal analysis 130 , the therapy 12 is analyzed and at least one evaluation parameter 30 is determined. On the basis of significance of being a measure for the inhibition of the neuronal activity, the evaluation parameter 30 is also called inhibition parameter 30 in the following.
In a parameter evaluation 140 , the inhibition parameter 30 is compared with reference parameters in order to determine the suitability of the therapy signal 12 for the therapy or treatment of the individual tinnitus with the tinnitus frequency 20 .
The reference parameters are based for example on reference signals, which have proven to be suitable or unsuitable for tinnitus therapy in empirical studies, wherein the reference parameters are specified by the inhibition 30 for the reference signals determined by means of the signal analysis 130 .
The result of the parameter evaluation 140 is transmitted to the client computer 44 via a user dialog 150 . The user dialog 150 simultaneously provides an audio data flow 160 with the therapy signal 12 for playback by means of the client computer 44 or an audio file 162 with the therapy signal 12 for storage on the client computer 44 .
The amplitude frequency path of the filter 120 is represented schematically in FIG. 2 in the form of a characteristic curve 60 . The horizontal axis of the frequency of the audio signal to be filtered and the vertical axis of the damping of the filter thereby match.
The characteristic curve 60 of the filter 120 has a band-stop filter 70 around a center frequency F0, which corresponds in particular with the individual tinnitus frequency 20 . The band-stop filter 70 has a therapeutic goal range or blocking range with a blocking range 22 , which is for example an octave or is specified as variable blocking width 22 . The blocking range defines a lower threshold frequency F2 of the therapeutic target range or respectively blocking range and an upper threshold frequency F3 of the therapeutic target range or respectively blocking range, wherein the blocking range is arranged for example on a logarithmic frequency scale symmetrically around the center frequency F0. The damping of the band-stop filter 70 , in particular the damping of the filter in the therapeutic target range, is determined in particular depending on the quantification word width M of a digital audio signal to be filtered 10 and is for example M*6 dB+2 dB.
Above and below the blocking range, the band-stop filter 70 has transition areas, which are characterized by the lower threshold frequency F1 of the band-stop filter 70 and the upper threshold frequency F4 of the band-stop filter 70 . The width of the transition areas is thereby dependent on the implementation of the respective filter 120 , wherein a decreasing width of the transition areas in the case of a digitally implemented filter 120 is generally connected with increased computing effort and thus with increased time effort during the creation of the therapy signal 12 . The filter 120 is preferably designed or configured such that the width of the transition areas is small compared to the blocking range 22 . For example, each of the widths of the transition areas is a quarter tone when the blocking range 22 is one octave or respectively six whole tone steps.
Outside of the transition areas, each characteristic curve 60 of the filter 120 has passbands, in which the audio signal to be filtered mainly remains unchanged. In these areas, the damping is correspondingly zero.
FIG. 3 shows an exemplary implementation of the digital filter 120 . Input parameters for the filter 120 are the original audio signal 10 , which is in particular one digital audio signal, the individual tinnitus frequency 20 as well as the blocking range 22 .
In a signal preparation 210 , the original audio signal 10 is decoded and, if applicable, converted to a linear PCM format (Pulse Code Modulation) if the original audio signal 10 is not yet available in such a format.
The audio signal prepared in this manner undergoes a normalization 212 in order to keep the signal-to-noise ratio of the filtered audio signal low. If the step response of the filter 120 produces overshoots, the audio signal is also reduced approximately by the height of the overshoot in a linear damping 214 in order to avoid distortions in the filtered audio signal.
Furthermore, the sampling rate of the audio signal 10 as well as the quantification word width M of the prepared audio signal are determined in a parameter determination 220 .
The actual filtering of the audio signal takes place by means of an FIR filter 250 through numeric folding with suitable filter coefficients, which were determined previously taking into consideration the sampling rate, the quantification word width M, the individual tinnitus frequency 20 as well as the blocking range 22 (block 240 ).
In a subsequent noise suppression 260 , the so-called dithering, digitalization roundings are randomized in the filtered audio signal. In a signal post-processing 270 , the filtered audio signal is then converted to a freely selectable data format and made available as a therapy signal 12 . For example, the data format of the original audio signal 10 is used.
FIG. 4 shows schematically a flow chart of an exemplary implementation of the signal analysis 130 . On the input side, the original audio signal 10 or the therapy signal 12 , the tinnitus frequency 20 as well as the blocking range 22 are supplied to the signal analysis 130 .
The audio signal 10 , 12 to be analyzed is analyzed in sections, wherein one section comprises for example 576 audio samples at a sampling rate of 44.1 kHz and is called a granule below. Moreover, if present, the left stereo channel and the right stereo channel of the audio signal can be analyzed individually.
Each granule of the audio signal 10 , 12 to be analyzed is analyzed in the frequency range on the basis of the functionality of human hearing. The modeling of human hearing is generally based on auditory filters with a different and usually relative bandwidth. These are for example the frequency groups according to Zwicker, i.e. the so-called bark scale, or the equivalent rectangular bandwidth, i.e. the so-called ERB scale (Equivalent Rectangular Bandwidth) according to Moore. Both the bark scale and the ERB scale are linked with the frequency non-linearly and selected such that the division of the scale into integer scale sections corresponds with the signal processing of human hearing. For a differentiated analysis, each scale section can respectively be divided into several, for example three, parts. Such a part is called a partition band below and has for example a width of ⅓ bark or ⅓ ERB.
In each granule of the audio signal 10 , 12 to be analyzed, an auditory energy contained in the partition band is determined for each partition band (block 310 ). This takes place for example using a Fast Fourier Transformation, FFT, and assuming a sound pressure level, which leads to a volume that is considered moderate when listening to the audio signal 10 , 12 . For example, the audio signal 10 , 12 to be analyzed is thereby scaled such that the maximum sound pressure level is approximately 70 dB.
Furthermore, a tonality is determined for each partition band in each granule (block 320 ). The tonality is a measure for whether a sound event is noise-like, i.e. wide-band, or tonal, i.e. narrow-band. It can be determined for example via the predictability or periodicity of the audio signal over time, wherein an observation of several successive temporal sections of the audio signal 10 , 12 to be analyzed is required. Alternative determination processes, for example based on the distribution of the sound energy in the frequency spectrum of the actually analyzed granule, in particular within the individual partition bands of the granule, are thus preferred.
If the actual partition band lies in full or in part outside of the therapeutic target range, then an excitation strength of the actual partition band determines an excitation strength first based on the auditory energy and the tonality (block 330 ), wherein it can be taken into consideration that noise-like sound events are perceived stronger or louder than tonal sound events at the same sound pressure. It can also be taken into consideration that higher frequencies are perceived weaker or less loud than deeper tones at the same sound energy in that for example the excitation strength is reduced when the actual partition band lies above the tinnitus frequency 20 or respectively above the therapeutic target range. The excitation strength is a measure for the stimulation of the neurons of the primary auditory cortex tonotopic to the actual partition band.
A damping strength is determined from the excitation strength for the actual partition band for all other partition bands (block 332 ), which is a measure for the lateral inhibition of the neurons respectively tonotopic to the other partition bands. In particular neuroacoustic or psychoacoustic spreading functions are used for this in particular. It is thereby taken into consideration in particular that the range of the lateral inhibition depends greatly on the excitation strength or the strength of the stimulation of the neurons tonotopic to the actual partition band. The greater the excitation strength, the greater the frequency range or respectively the number of neighboring partition bands, in which the lateral inhibition shows relevant effects. If empirically psychoacoustic spreading functions are used, a correction based on the frequency curves of the same volume (isophones) according to ISO 226:2003 thus preferably takes place in order to compensate in particular for frequency-evaluating properties of the outer, middle and inner ear.
If the actual partition band lies within the therapeutic target range, which is defined in particular by the tinnitus frequency 20 and the blocking range 22 , an excitation strength is also determined (block 334 ). It is thereby then differentiated whether the audio signal 10 , 12 to be analyzed is an unfiltered or original audio signal 10 or a therapy signal 12 .
In the case of an unfiltered audio signal 10 , the excitation strength is set to zero. The unfiltered audio signal 10 is treated correspondingly as if it had been processed with an ideally damping band-stop filter with infinitely narrow transition areas.
In the case of a filtered audio or a therapy signal 12 , the excitation strength as in the case of a partition band is determined outside the therapeutic target range or respectively blocking range.
The analysis steps 310 , 320 , 330 , 332 , 334 described above are repeated for all partition bands of a granule. An excitation strength and a plurality of damping strengths are then available for each partition band of the granule.
The damping strengths for each partition band are combined respectively into a total damping strength for this partition band (block 340 ). This takes place for example by means of intensity addition, by means of non-linear addition or by means of maximum value calculation.
Optionally, the excitation strengths and the total damping strengths of all partition bands of a granule are corrected with respect to such one or more other granules (block 350 ).
Through a correction with respect to one or more preceding granules, it can be taken into consideration for example that a strong excitation or damping of a neuronal areal continues to have an effect for a short time even after fading of the stimulus.
Accordingly, it can be taken into consideration through correction with respect to a simultaneous granule for another channel of the audio signal 10 , 12 that, if applicable, an excitation of the neurons responsible for an ear results in a damping of the neurons responsible for the other ear.
The total damping strengths of those partition bands lying within the therapeutic target range are subsequently combined into an inhibition parameter 30 (block 360 ), which takes place for example by means of intensity addition, by means of non-linear addition or by means of maximum value calculation. If the audio signal to be analyzed is a therapy signal 12 , the excitation strengths of the partial bands lying within the blocking range with the opposite sign are also included.
An inhibition parameter 30 is thus then available for each granule, which is a measure for an inhibition of neuronal activity in the primary auditory cortex of the actual granule of the analyzed therapy signal 12 or respectively of a therapy signal created from the analyzed unfiltered audio signal 10 .
Additional parameters, which also correlate with the inhibition of neuronal activity in the primary auditory cortex, can be determined from the inhibition parameters 30 .
In particular, the simultaneous granules of the two stereo channels can be combined into a sum parameter and into a difference parameter. The sum parameter, for which the inhibition parameters 30 of the granules of both stereo channels are considered in particular with the same signs, is for example a measure for the therapy potential of the audio signal 10 , 12 . This also applies if the therapy takes place by means of a loudspeaker and thus both ears are both equally exposed to the two stereo channels. The difference parameter, for which the inhibition parameters 30 of the granules of both stereo channels are considered in particular with different signs, specifies in contrast how the therapy potential of the audio signal 10 , 12 is distributed to the stereo channels. This is interesting in particular for when the therapy takes place with headphones and thus each ear is exposed to one stereo signal.
The inhibition parameters 30 , the sum parameters or the difference parameters of all granules of an audio signal 10 , 12 can also be combined into one total parameter, which accordingly specifies in particular the therapeutic potential of the total audio signal 10 , 12 . This takes place for example by means of intensity addition, non-linear addition, maximum value formation or even average value formation.
FIG. 5 shows schematically a further implementation of the method according to the invention, which differs from the implementation according to FIG. 1 in that the signal analysis 130 is first performed and the inhibition parameter 30 is determined. It is then evaluated in the parameter evaluation 140 , wherein the therapy signal 12 only takes place by means of the filter 120 when the parameter evaluation 140 has produced sufficient therapeutic suitability of the original audio signal 10 .
The implementations according to FIG. 1 and FIG. 5 can also be combined, wherein the signal analysis 130 is then executed both on the original audio signal 10 as well as on the therapy signal 12 .
FIG. 6 shows a further embodiment of the method according to the invention, which is suitable in particular for real-time applications. The filter 120 and the signal analysis 130 are hereby executed in parallel so that the therapy signal 12 and the inhibition parameter 30 are available simultaneously.
The method according to the invention is also suitable for preparing or processing audio signals for a tinnitus therapy for use with playback device that have a non-linear frequency path.
For example, commercially available headphones often have a non-linear frequency path due to their design or manipulated in a targeted manner, wherein the non-linearity is generally homogeneous for all models of a series and is correspondingly known or at least determinable.
Through use of a non-linear playback device or a playback device with non-linear frequency path, the therapeutic qualities of the audio signal provided for tinnitus therapy are reduced and the assessment of the therapeutic suitability of the audio signal is falsified according to the above description.
In order to prevent this, an optional correction of the audio signal provided for the therapy is provided within the framework of the invention. An exemplary design of this correction is described in FIGS. 7 a and 7 b.
FIG. 7 a shows schematically a section of a flow chart of a filter 120 for a method according to the invention. The filter 120 corresponds with the filter 120 shown in FIG. 3 , wherein the section shown in FIG. 7 a replaces the blocks 214 , 240 and 250 in FIG. 3 .
In front of the FIR filter 250 , a further correction filter 251 , designed for example as an FIR filter, is used, by means of which a correction is performed with respect to the non-linearity of the playback device. For example, filter coefficients 241 or correction coefficients 241 from a database are used for this, which are adjusted to the playback device to be corrected. Such frequencies, which are played back in a damped manner due to the non-linearity of the playback device, are increased by the correction filter 251 in the filtered audio signal. Such frequencies, which are played back excessively or strengthened due to the non-linearity of the playback device, are correspondingly damped in the filtered audio signal.
The occurring correction in the audio signal 12 provided for the therapy is also preferably taken into consideration in the determination of the inhibition parameter 30 , as shown in FIG. 7 b . FIG. 7 b shows a section of a flow chart comparable with FIG. 4 , wherein for example the upper part of the representation in FIG. 4 is replaced by the section in FIG. 7 b.
A non-linearity simulation 311 is performed here before the determination of the auditory energy (block 310 ), in order to correctly consider the non-linearity of the playback device. The non-linearity simulation 311 is thereby based on the correction coefficient 241 already used for the correction filter 251 .
All named characteristics, including those taken from the drawings alone and also individual characteristics, which are disclosed in combination with other characteristics, are considered alone and in combination as essential for the invention. Embodiments according to the invention can be realized by individual characteristics, or a combination of several characteristics. | A method for processing audio signals in particular for a therapy of subjective tinnitus with an individual tinnitus frequency. The method includes: providing a first audio signal, determining a blocking range in the frequency spectrum of the first audio signal with a predefinable frequency width, creating a second audio signal from the first audio signal using a filter, and determining an auditory energy of the first audio signal or the second audio signal within at least one predefined therapeutically applicable frequency range and specifying an evaluation parameter for the second audio signal. | 0 |
CROSS-REFERENCE TO RELATED APPLICATION
This application is the National Stage of international Application No. PCT/CN2014/093492, filed Dec. 10, 2014, which claims the benefit of priority to Chinese Patent Application No. 201410012557.7 titled “BEARING LIMITING SYSTEM AND LIMITING METHOD”, filed with the Chinese State Intellectual Property Office on Jan. 10, 2014, the entire disclosures of which are incorporated herein by reference.
TECHNICAL FIELD
This application relates to a hearing position-limiting system and a position-limiting method.
BACKGROUND
In the conventional technology, limitation to a bearing inner race at one side is typically implemented by providing a shaft shoulder on a shaft, and the technique of limitation to the bearing inner race at the other side mainly includes the following kinds. One kind is to provide a groove or screw threads on the shaft, and secure a position-limiting component via this groove or the screw threads, and then limit the bearing by the position-limiting component; another kind is to limit the bearing by an interference fit; the third kind is to limit the bearing by adhesion; and the fourth kind is to mount a shaft cap on a shaft end.
The position limiting implemented by the interference fit and the adhesion have low reliability. Providing the groove or the screw threads on the shaft to limit the bearing inner race may reduce the strength of the shaft, thereby affecting the performance and the operation safety of the entire mechanical equipment. The method of mounting a shaft cap on a shaft end is not applicable to a bearing mounted on a long shaft. For the bearing mounted on the long shaft, the long shaft is generally designed to be a tapered shape, and an end of the shaft far away from the load end generally has a small shaft diameter.
SUMMARY
In order to eliminate the defects in the conventional technology such as low reliability, affecting the strength of the shaft and further affecting the performance and operation safety of the mechanical equipment, and inapplicable to a bearing mounted on a long shaft, a bearing position-limiting system and a position-limiting method are provided according to the present application.
According to an aspect of the present application, a bearing position-limiting system is provided according to the present application, which includes a position-limiting projection, a bearing inner race and a force transferring part arranged between the position-limiting projection and the bearing inner race. An inner diameter of the bearing inner race is larger than an outer diameter of the position-limiting projection.
According to another aspect of the application, a bearing position-limiting method is provided, which includes: applying a radial action force to a bearing inner race along a shaft at a mounting position of a bearing to a proximal end from a distal end by taking an position-limiting projection integrally formed with the shaft as a force application point, wherein an outer diameter of the position-limiting projection is smaller than an inner diameter of the bearing inner race.
At least the following beneficial effects are achieved by the embodiments of the present application.
The bearing position-limiting system according to the embodiments of the present application is convenient for installation, and is capable of achieving effective position-limiting to the bearing inner race without affecting the strength of the shaft and interfering the assembly and disassembly of the bearing, and is particularly applicable to the hearing mounted on a long shaft. The bearing position-limiting method according to the embodiments of the present application is easy to operate, and has low requirement to the operating environment and capability of the operators.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other objects and features of the present application will be further described clearly by means of the following description in conjunction with the drawings, in which:
FIG. 1 is a first schematic view showing the structure of a bearing position-limiting system according to an embodiment of the present application;
FIG. 2 is a second schematic view showing the structure of the bearing position-limiting system according to the embodiment of the present application;
FIG. 3 is a third schematic view showing the structure of the bearing position-limiting system according to the embodiment of the present application;
FIG. 4 is a fourth schematic view showing the structure of the bearing position-limiting system according to the embodiment of the present application;
FIG. 5 is a first cross-sectional schematic view showing the structure of a rigid ring of the bearing position-limiting system according to the embodiment of the present application; and
FIG. 6 is a second cross-sectional schematic view showing the structure of the rigid ring of the bearing position-limiting system according to the embodiment of the present application.
REFERENCE NUMERALS IN THE DRAWINGS
1 —position-limiting projection,
2 —bearing inner race,
3 —force transferring part,
4 —first rigid component,
5 —second rigid component,
6 —connecting component,
7 —stuck part,
8 —bolt,
a—bolt hole,
b—through slot,
c—half through slot.
DETAILED DESCRIPTION
The bearing position-limiting system according to the embodiments of the present application is applicable to a bearing mounted on a long shaft, and the long shaft is in a tapered shape, and an end of the shaft far away from a load end has a smaller shaft diameter. In the present application, an end which is far away from the load end and has a small shaft diameter is defined as a distal end, and an end which is close to the load end and has a large shaft diameter is defined as a proximal end. A set of bearing position-limiting system is designed according to the present application just by utilizing the feature that the long shaft is in the tapered shape.
A first embodiment is described hereinafter.
As shown in FIG. 1 , which is a first schematic view showing the structure of the bearing position-limiting system according to an embodiment of the present application, the bearing position-limiting system according to the embodiment includes a position-limiting projection 1 , a bearing inner race 2 and a force transferring part 3 . The force transferring part 3 is arranged between the position-limiting projection 1 and the bearing inner race 2 , and an inner diameter of the bearing inner race 2 is larger than an outer diameter of the position-limiting projection 1 . Preferably, the position-limiting projection 1 is integrally formed with a shaft.
Specifically, the position-limiting projection 1 is located at a certain distance from a bearing mounting position, and the force transferring part 3 abuts against the position-limiting projection 1 and the bearing inner race 2 , thus transferring the position-limiting action of the position-limiting projection 1 to the bearing inner race 2 . Preferably, the force transferring part 3 is a ring-shaped structure, and an inner diameter of the force transferring part 3 at a side close to the position-limiting projection 1 is smaller than the outer diameter of the position-limiting projection 1 , thus, the force transferring part 3 can abut against the position-limiting projection 1 . The position-limiting projection 1 may be in a shape of a projected baffle ring integrally formed with the shaft.
Further, in order to ensure the assembly and disassembly of a bearing outer race and a roller are not affected, the inner diameter of the bearing inner race 2 may be smaller than a maximum outer diameter of the force transferring part 3 , and an outer diameter of the bearing inner race 2 may be larger than the maximum outer diameter of the force transferring part 3 .
The force transferring part 3 may be at least one integrally formed circular ring and/or at least one multi-piece split circular ring. The force transferring part 3 may be an elastic component and/or a rigid component. If the force transferring part 3 is an elastic component, the elastic component may be mounted between the position-limiting projection 1 and the bearing inner race 2 from an end, having a small diameter, of the long shaft with the aid of the elasticity. If the force transferring part 3 is a rigid component, the force transferring part 3 may also be mounted between the position-limiting projection 1 and the bearing inner race 2 from the end, having a small shaft diameter, of the long shaft after being heated, and then the force transferring part 3 can abut against the position-limiting projection 1 and the bearing inner race 2 after being cooled. In practical applications, however, the force transferring part 3 is preferably a structure spliced by multiple pieces in a circumferential direction, i.e., a multi-piece snapping circular ring. Thus, there is no need to mount the spliced structure along an axial direction. As shown in FIG. 1 , the force transferring part 3 is a split fixed ring formed by two opposite pieces. After the bearing inner race is mounted, the split fixed ring formed by two opposite pieces is mounted between the projection 1 and the bearing inner race 2 , and threaded holes are provided at the joints of the fixed ring, and the two pieces are connected by a hexagon socket-head bolt.
In the bearing position-limiting system according to the embodiment, the position-limiting projection is designed on the long shaft to have an outer diameter not larger than the inner diameter of the bearing inner race, and the force transferring part transfers the position-limiting action to the bearing inner race, effectively and mechanically securing the bearing inner race without affecting the assembly of the bearing inner race and the strength of the long shaft.
A second embodiment is described hereinafter.
As shown in FIG. 2 , which is a second schematic view showing the structure of the bearing position-limiting system according to a second embodiment of the present application, the difference between the second embodiment and the first embodiment lies in that the force transferring part 3 includes a first rigid component 4 and a second rigid component 5 . Specifically, the first rigid component 4 is located close to the bearing inner race 2 , and the second rigid component 5 is located close to the position-limiting projection 1 . Preferably, the first rigid component 4 is a rigid ring mounted on the shaft by an interference fit (i.e., the first rigid component is an interfering ring) and abuts against the bearing inner race 2 . The second rigid component 5 may also be the same as that in the first embodiment, which is in a form of a two-piece or multi-piece split fixed ring. As shown in FIG. 4 , the first rigid component 4 and the second rigid component 5 may be connected together by a bolt 8 . Specifically, threaded holes may be provided in the first rigid component 4 in the axial direction, in addition, the threaded holes may also be provided correspondingly on the second rigid component 5 in the axial direction. The first rigid component 4 and the second rigid component 5 are connected together by the bolt 8 so as to form a single piece, and finally the second rigid component 5 abuts against the position-limiting projection 1 .
The interfering ring prevents an axial movement of the bearing inner race by means of the interference fit, however, this method still has a risk of failure. Thus, a two-piece split fixed ring is further provided to cooperate with the interfering ring, which effectively prevents the failure of the interfering ring, and further effectively prevents the axial movement of the bearing inner race.
A third embodiment is described hereinafter.
As shown in FIG. 3 , which is a third schematic view showing the structure of the hearing position-limiting system according to a third embodiment of the present application, the difference between the third embodiment and the second embodiment lies in that the first rigid component (i.e. the interfering ring) 4 is located at a certain distance from the second rigid component 5 , and the first rigid component 4 and the second rigid component 5 are connected together by a connecting component 6 , and specifically, the connecting component 6 may be a bolt. In an using process, the second rigid component 5 is mounted after the bearing and the first rigid component 4 are mounted, and the first rigid component 4 and the second rigid component 5 are connected by the bolt passing through both of them, and are secured by a nut finally. In this way, a certain gap exists between the first rigid component 4 and the second rigid component 5 , which ensures that the second rigid component 5 can be mounted on the shaft smoothly, and also saves the material of the bearing position-limiting component. As with the above embodiments, the second rigid component 5 may also be in a form of a two-piece or multi-piece split fixed ring same with that in the first embodiment. As a further improvement to this embodiment, the first rigid component (i.e., interfering ring) 4 may be dispensed, and only the second rigid component 5 is left, thus, the second rigid component 5 directly abuts against the bearing inner race by the bolt connecting with the second rigid component 5 .
A fourth embodiment is described hereinafter.
This embodiment mainly refers to a further improvement to the position-limiting projection 1 , as shown in FIG. 3 . The position-limiting projection 1 may be in a form of one or more projected blockers arranged in a circumferential direction, and the outer diameter of the position-limiting projection 1 is generally smaller than (at least not larger than) the inner diameter of the bearing inner race 2 , which ensures that the assembly and disassembly of the bearing inner race 2 are not affected. Each of the projected blockers may be in a square shape (a square shape as shown in the drawings) or in a circular-arc shape.
If the blockers are provided on the shaft, the entire force transferring part 3 or the second rigid component 5 may be designed as a rigid ring with a particular structure, and the rigid ring is a tapered ring-shaped structure (as shown in FIG. 6 ) which conforms to the profile of the shaft. The rigid ring is provided with one or more through slots and one or more half through slots (i.e., a stuck part 7 , as shown in FIG. 3 ) which match the blockers on the shaft in size and number, and the rigid ring is also provided with the threaded holes in the axial direction. The outer diameter of the rigid ring should not be larger than the outer diameter of the bearing inner race, which ensures that the rigid ring does not affect the assembly and disassembly of the bearing outer race and the roller. FIG. 5 is a first cross-sectional schematic view showing the structure of a rigid ring according to the fourth embodiment of the present application (taken along the plane where the circumference is located), and FIG. 6 is a second cross-sectional schematic view showing the structure of the rigid ring according to the fourth embodiment of the present application (taken along the plane where the axis is located). As shown in FIGS. 5 and 6 , the rigid ring shown in the drawings is provided with a through slot b, a half through slot c and a bolt hole a.
Taking the structure shown in FIG. 3 as an example, the second rigid component 5 is designed to be a rigid ring having a particular structure, and is in cooperation with the interfering ring as the first rigid component 4 , so as to achieve position limitation. The mounting process is as follows. The second rigid component 5 is mounted after the interfering ring is mounted, and firstly, the through slot b is aligned with one of the projected blockers on the shaft, and after the second rigid component 5 is completely pushed to a right side of the projected blocker on the shaft, the second rigid component 5 is rotated by a certain angle so as to allow the half through slot c on the second rigid component 5 to be aligned with the projected blocker on the shaft, and then the baffle ring is moved leftward, which allows the projected blocker to abut against the half through slot c. In addition, as a further improvement, the half through slot c may also be designed to be an L shape to prevent the rigid ring from moving towards the shaft end continually.
After the second rigid component 5 is mounted, the bolt 8 as a connecting component 6 is screwed into the threaded hole a. The bolt 8 may be a hexagon socket flat-ended bolt, and multiple bolts 8 may be provided and the number of the bolts 8 screwed-in can be selected based on the outer diameter of the shaft. After the bolt 8 is screwed, the flat end of the bolt abuts against the first rigid component 4 , and then the bolt 8 is rotated continually. Since the second rigid component 5 also has screw threads, rotating the bolt 8 continually would push the second rigid component 5 to move leftward until the projected blocker on the shaft abuts against the half through slot c in the second rigid component 5 , thus the entire system is pressed tightly, and when the bolt 8 is rotated in place, a washer and a nut may be mounted for the final securing.
The technical solutions of the present application are introduced by the above four embodiments, and improvements adopted in various embodiments may also be combined mutually. Therefore, in general, the various variants for the above embodiments are summarized as follows. The rigid ring may not only solely act as the force transferring part 3 , specifically, one end of the rigid ring is engaged with the blockers, and the other end of the rigid ring is connected to the bearing inner race, but also form the force transferring part 3 together with at least another rigid component, and the rigid ring (i.e., the second rigid component 5 ) as one end of the force transferring part is engaged with the blockers, the other rigid ring (i.e., the first rigid component 4 ) as the other end of the force transferring part abuts against the bearing inner race. The second rigid component 5 and the first rigid component 4 may not abut directly, but by a connecting component 6 . As long as a structure may achieve applying an axial acting force along the shaft to the bearing inner race 2 to a proximal end from a distal end and take the position-limiting projection 1 as a force application point, the intended object of the present application can be achieved by the structure.
As an implementation, an elastic component (e.g., a spring) may also be provided between the projected blockers or the projected baffle ring (i.e., the position-limiting projection 1 ) and the bearing inner race 2 as an implementation of the three transferring part 3 . The elastic component has two ends respectively in connection with the position-limiting projection 1 and the bearing inner race 2 . Alternatively, the elastic component is only a portion of the force transferring part 3 , and forms the force transferring part 3 together with other rigid components. For example, one end of the elastic component is in connection with the position-limiting projection 1 , and the other end of the elastic component is in connection with the rigid ring mounted with the interference fit on the shaft, and the interfering rigid ring is in connection with the bearing inner race. Thus, the limitation to the bearing inner race 2 is achieved by taking the position-limiting projection 1 as a force application point.
As an implementation, the split rigid ring formed by the two opposite pieces may be mounted between the position-limiting projection 1 and the bearing inner race 2 , and one or more threaded holes are designed in the two opposite pieces so as to connect the two split opposite pieces to form an entire circle, further, one or more threaded holes are designed in the rigid ring in the axial direction. An inner diameter of the rigid ring is in an clearance fit with the shaft such that the rigid ring is movable along the shaft, meanwhile an outer diameter of the rigid ring is not larger than the outer diameter of the bearing inner race 2 , which ensures that the rigid ring does not interfere the assembly and disassembly of the bearing outer ring and the roller.
After the bearing inner race 2 is assembled, the split rigid ring formed by the two opposite pieces may then be mounted. After the split two pieces are connected into the entire circle by the bolt, the hexagon socket set screw with flat point is screwed into the threaded hole of the rigid ring. The set screw is screwed until the set screw abuts against the hearing inner race 2 , at this time, the set screw is screwed continually such that the rigid ring moves towards the shaft end until the rigid ring abuts against the position-limiting projection 1 . For example, the half through slot on the rigid ring completely abuts against the blocker on the shaft, thus completely securing the bearing inner race 2 . In such a case, a washer and a nut are mounted on the set screw, thereby achieving the limitation and securing to the bearing inner race 2 .
In the above embodiments, an interfering ring may also be additionally mounted between the bearing inner race 2 and the rigid ring. After the bearing is, the interfering ring is mounted to abut against the bearing, in such a case, the set screw is allowed to abut against the interfering ring to achieve redundancy mechanical securing to the bearing inner race 2 . Apparently, those skilled in the art may appreciate that adding the interfering ring based on other embodiments is advantageous to the object of the present application. For example, after the interfering ring (i.e., the first rigid component 4 ) is provided to abut against the bearing inner race 2 , the second rigid component 5 is provided between the interfering ring and the position-limiting projection on the shaft, and the second rigid component 5 is secured to the interfering ring by the bolt. In such a case, the second rigid component 5 may be an arc-shaped steel block adapted to the long shaft of an axle. In the case that the position-limiting projection 1 on the shaft is in a form of multiple projected blockers, corresponding number of arc-shaped steel blockers may be provided, and an independent arc-shaped steel blocker is provided between each position-limiting projected blocker and the interfering ring. The arc-shaped steel blockers may also be less than the position-limiting projected blockers. That is to say, some adjacent arc-shaped steel blockers arranged between multiple position-limiting projected blockers and the interfering ring are integrally formed. In the case that the position-limiting projection 1 is a projected ring, the number of the arc-shaped steel blocks may be selected according to practical requirements.
There may be a variety of solutions for the design of the projected blocker, in addition to the square blocker, the projected blocker may also be in a circular arc shape, or may not be the scattered blockers but may be designed as a baffle ring in an entire circle shape. The shape of the through slot and the shape of the half through slot on the rigid ring may also be changed correspondingly.
Although the present application has been represented and described with reference to the preferred embodiments, it should be understood that, for the person skilled in the art, various modification and variations may be made to these embodiments without departing from the spirit and the scope of the present application defined by appended claims. | Disclosed is a bearing limiting system. The limiting system comprises a limiting bulge formed integrally with a shaft, a bearing inner race, and an acting force conduction part, wherein the acting force conduction part is arranged between the limiting bulge and the bearing inner race, and the inner diameter of the bearing inner race is larger than the outer diameter of the limiting bulge. The bearing limiting system is convenient in installation, can realize the effective limiting of a bearing inner race while not affecting either the strength of the shaft or the assembly and disassembly of the bearing, and is especially suitable for a bearing with a long shaft. | 5 |
BACKGROUND
The invention generally relates to methods of recovering material from containers.
The products of the chemical, biotechnological, and pharmaceutical industries can be the result of immense investments of money, time, and effort. Occasionally a manufacturing or human error can create a problem. For example an unsafe contaminant could accidentally be introduced into the product, or a batch of the product could be accidentally packaged into non-sterile containers, where sterility of the product is required for safety. It may be desirable to recover as much of the product as possible, and then purify or sterilize it as appropriate.
SUMMARY
In the embodiments described here, liquid can be recovered from stoppered vials by providing the vials upside down in a holding cassette over upwardly extending hollow needles. The needles puncture the stoppers in the vials and draw the liquid through a manifold to a vessel. The cassette with multiple vials can be manually provided in a holder and manually removed from the holder after the liquid is removed. The recovery process can be initiated with a safety feature that requires two simultaneous actions, such as two buttons to be pushed by two hands to prevent inadvertent actuation. The system preferably uses a peristaltic pump, which is preferably operated with a foot pedal actuation.
Other features and advantages will become apparent from the following detailed description, drawings, and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram showing the components of the recovery system.
FIG. 2 is a detailed diagram of the vial holder and needle assembly.
DETAILED DESCRIPTION
The systems described here are directed to methods of recovering expensive or dangerous materials from sealed containers safely, nearly completely, and with high throughput. They can be used with benign materials or with materials that are unsafe for human contact; it could be toxic, explosive, mutagenic, or carcinogenic, for example, such that human involvement in the recovery process should be kept to a minimum.
FIG. 1 is a schematic diagram showing components of an embodiment of a recovery system. The system has three main components: recovery device 100 that holds sealed vials containing a solution, a peristaltic pump 170 that pumps the solution out of the vials, and a recovery tank 190 that receives the pumped solution. In recovery device 100 , vial holder cassette 110 holds solution-containing vials 120 upside down, so the solution flows to the bottom. Vials 120 can be made of any sturdy material, such as glass or plastic, which is preferably transparent so that recovery of the material can be monitored.
Caps or stoppers seal vials 120 , preventing the solution from leaking during normal storage and transportation. The stoppers are made of a material that can be pierced with a needle to allow the solution to be withdrawn without removing the stopper. The stopper preferably “re-seals” after being punctured. Rubber is an example of a useful stopper material. These features of the stopper reduce the risks of human contact with a dangerous material, of further contamination, and of losing material during recovery process.
A needle holder 130 securely holds a row of needles 140 directly beneath vials 120 . The needles 140 have a hollow bore, and are sufficiently strong to pierce the stoppers of vials 120 without breaking. If a needle does break it can be replaced easily by twisting it off and twisting a new one on. When a user presses two cylinder push buttons 160 , an air cylinder 150 raises needle holder 130 , preferably to a height where the tips of the needles 140 barely puncture the vial stoppers. This way as solution is drawn out of the vial, the tips of the needles 140 stay immersed in the solution until nearly all of the solution is withdrawn.
Tubing 180 connects each of the needles 140 to peristaltic pump 170 and then to recovery tank 190 . Pump 170 is designed such that the solution does not come in contact with internal pump components, but is transmitted via continuous tubing 180 into recovery tank 190 . Using such a pump allows the tubing 180 to be sterilized or discarded after the recovery process is completed, and also minimizes the risk of human exposure, contamination of the solution by the pump, contamination of the pump by the solution, and loss of the material into the pump. Recovery tank 190 has a vent filter 195 that allows gases, but not the liquid, to escape, and stores the solution until the user is ready to further process or purify it. In some embodiments, the liquid is reprocessed or purified by any needed means including by heating, filtering, disinfecting light, mixture with other materials, or any other desired process.
FIG. 2 illustrates in greater detail the components of recovery device 100 , with the rest of the system as shown in FIG. 1 . Vial holder cassette 110 holds the vials 120 stopper side down. A user locks cassette 110 into place in the device, where it is securely held in all three dimensions. Side rails 118 hold cassette 110 in place in the horizontal plane. Vial stop 115 and side rail adjustments 112 hold cassette 110 in place vertically. Vial stop 115 also prevents vials 120 from moving upwardly when the needles puncture the stoppers. Cassette 110 is easily interchangeable, allowing recovery of solution from a large number of vials in a short amount of time. While the cassette is shown with one row of 10 vials, it could be used with other plural numbers of vials in other two-dimensional arrays. The cassette can be manually provided with no system and fixed in place without a carousel or other moving device, although automated moving systems could be used. The vials can have a narrower neck and wider body, unlike a test tube, thereby creating a shoulder that can rest in the cassette.
As described previously, needle holder 130 securely mounts needles 140 to be used for solution recovery. Holder 130 approximately centers each needle tip 145 on the stopper of corresponding vial 120 . The device holds needle holder 130 in place in all three dimensions. Guide rods 135 hold needle holder 130 in place in the horizontal plane. The vertical position of air cylinder 150 determines the vertical position of needle holder 130 . To adjust the vertical height of 130 , i.e. to controllably puncture the vial stoppers with needles 140 , the user simultaneously pushes two push buttons 160 . Two buttons are provided as a safety measure, in order to keep the user's hands away from the moving needles 140 and to prevent accidental starting. Other safely methods could be used, preferably including two simultaneous actions to start the process. Needle holder 130 stays raised as long as both buttons 160 are pressed, and then lowers when buttons 160 are released. When the user presses buttons 160 , a valve (not shown) opens, allowing compressed air at about 100 psi to raise air cylinder 150 to a pre-set height appropriate to the size of vials 120 . Once needles 140 pierce the stoppers at the appropriate height, the user activates peristaltic pump 170 with a foot switch (not shown). The needles 140 connect to manifold 155 with tubing 180 , which connects to pump 170 via additional tubing 180 as illustrated in FIG. 1 .
In one use, mass balances were used to monitor the yield of solution recovery, by weighing the vials before and after recovery, and it was found that the system recovered more than 95% of the material from 2 mL vials. Each cassette holds 10 vials, and by interchanging cassettes the device can be used to recover material from about 2000 vials per hour. The cassette is not limited to this size, and can be made as large or as small as needed to hold the desired size and number of vials. 2 mL is only provided as an example vial size, since it is commonly used for doses of drug solutions. Vials would not need to be used at all, but any container with a section that could be punctured without breaking or leaking could be used.
In the described system the user locks the cassettes into place and controls the needle height, but an automated system for exchanging cassettes and controlling the needle height could be implemented and would allow for even faster throughput of vials. Also, while the described recovery system moves the needles to puncture the vials, the needles could also be held fixed and the vials moved downwardly instead.
A solution is not the only material that can be recovered from sealed vials with the described system. If the vial contains a solid, or a liquid that is too viscous to pump out, the system can be used to introduce into the vial an appropriate solvent that dissolves the material. This is done by switching the recovery tank with a container of the solvent, and setting the pump to operate in reverse. The cassette holds the vials as usual, and the user presses the push buttons to raise the needles up to puncture the stoppers. Then the user activates the pump, which pumps solvent into the vials. This creates a solution suitable for recovery as usual. The user releases the pump and lowers needles, and then switches the system back to its original configuration, and operates it as described above. The switching can be automated.
The needles 140 , manifold 155 , tubing 180 , and recovery tank 190 are the only components that come in contact with the material, and are preferably non-reactive with the material. If the system is used to recover different materials, the tubing, manifold, needles, and tank should be changed for use with each different material to avoid cross-contamination and also potential reactivity. The pump itself does not need to be peristaltic, but any pump that has the functionality of isolating the solution from contamination in the pump could be used.
The system described here can be used with any liquid that should be recovered, including liquids that are expensive and/or potentially harmful, such as anti-cancer drugs.
Other aspects, modifications, and embodiments are within the scope of the following claims. | A system allows for the safe, rapid, efficient recovery of a drug solution from sealed vials. The system is closed so that highly potent compounds can later be recovered and reworked without large investment in further engineering controls. The system includes three main components: a recovery device that holds sealed vials containing a solution, and provides means to access the contents of the vials; a peristaltic pump that pumps solution out of the vials; and a recovery tank that receives the pumped solution. | 1 |
FIELD OF THE INVENTION
The present invention is generally directed to intervertebral or interspinous process implants, systems and kits including such implants, methods of inserting such implants, and methods of treating spinal stenosis or for alleviating pain or discomfort associated with the spinal column.
BACKGROUND OF THE INVENTION
Occurrences of spinal stenosis are increasing as society ages. Spinal stenosis is the narrowing of the spinal canal, lateral recess or neural foramen, characterized by a reduction in the available space for the passage of blood vessels and nerves. Clinical symptoms of spinal stenosis include extremity pain, radiculopathy, sensory or motor deficit, bladder or bowel dysfunction, and neurogenic claudication. Pain associated with such stenosis can be relieved by surgical or non-surgical treatments, such as medication, physical therapy, back braces and the like. While spinal stenosis is generally more prevalent of the elderly, it can occur in individuals of all ages and sizes.
There is a need for implants that may be placed between spinal processes for minimally invasive surgical treatment of spinal stenosis.
SUMMARY OF THE INVENTION
Certain embodiments of the present invention are generally directed to minimally invasive implants, in particular, interspinous process implants or spacers. Other embodiments of the invention are further directed to systems and kits including such implants, methods of inserting such implants, and methods of alleviating pain or discomfort associated with the spinal column.
Some embodiments of the present invention provide spacers or implants and methods for relieving pain and other symptoms associated with spinal stenosis, by relieving pressure and restrictions on the blood vessels and nerves. Such alleviation of pressure may be accomplished in the present invention through the use of an implant placed between the spinous process of adjacent vertebra.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be more readily understood with reference to the embodiments thereof illustrated in the attached figures, in which:
FIG. 1 is a perspective view of one embodiment of an implant according to the invention for creating, increasing, or maintaining distraction between adjacent spinous processes;
FIG. 2 is a side view of the implant of FIG. 1 ;
FIG. 3 is an end view of the implant of FIG. 1 ;
FIGS. 4-7 are side views demonstrating various steps according to one embodiment of a method of installation of the implant of FIG. 1 ;
FIGS. 8-9 are front and rear perspective views of another embodiment of an implant according to the invention;
FIG. 10 is a perspective view of one embodiment of a ring attachable to the implant of FIGS. 8-9 ;
FIG. 11 is a front perspective view of another embodiment of an implant according to the invention;
FIG. 12 is a partial front perspective view of another embodiment of an implant according to the invention;
FIG. 13 is a partial front perspective view of another embodiment of an implant according to the invention;
FIG. 14 is a partial front perspective view of another embodiment of an implant according to the invention;
FIG. 15A is a partial cross-sectional side view of another embodiment of an implant according to the invention;
FIG. 15B is a perspective view of the embodiment of FIG. 15A ;
FIGS. 16-23 are perspective views demonstrating various steps according to one embodiment of a method of installation of the implant of FIG. 1 ;
FIGS. 24-25 depict a perspective view of the implant of FIG. 1 shown in an implanted position; and
FIG. 26 is a perspective view of one embodiment of a removal tool according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
Embodiments of the invention will now be described. The following detailed description of the invention is not intended to be illustrative of all embodiments. In describing embodiments of the present invention, specific terminology is employed for the sake of clarity. However, the invention is not intended to be limited to the specific terminology so selected. It is to be understood that each specific element includes all technical equivalents that operate in a similar manner to accomplish a similar purpose.
Implants
Some embodiments of the present invention are directed to minimally invasive implants, in particular, interspinous process spacers. Implants in accordance with the invention may come in many shapes and sizes. The illustrative embodiments provided herein-below provide guidance as to the many types of implants that may be advantageously used in accordance with the present invention. In particular, the implants are adapted such that their insertion technique (including methods of the present invention) is minimally invasive, and generally simpler, and/or safer than those installed in open or more invasive techniques. According to one aspect, implants according to the present invention may be advantageously inserted into a patient as an out-patient procedure.
Embodiments of the present invention include implants adapted to be placed between first and second adjacent spinous processes. The implants may be adapted such that after insertion of an implant into a patient, a portion of the implant maintains a desired amount of distraction or spacing between two adjacent spinous processes. The implants or portions thereof that substantially maintain a desired spacing between spinous processes are also referred to herein as “spacers.” In various embodiments described herein, the implants may include spinous process support surfaces, indented portions or saddle portions spaced apart by a distance (a) ( FIG. 2 ), which generally corresponds to a desired distance for distraction or spacing of two adjacent spinous processes. Other embodiments similarly provide a desired distance for distraction or spacing of two adjacent spinous processes. Depending on the material and/or design of the implant, the desired distraction or spacing distance may vary somewhat after insertion, for example if a patient moves its spine into a position that causes further distraction. For example, in certain embodiments the implant may be resiliently compressible or expandable in the cranial-caudal direction such that the implant may support and or adjust to dynamic movement of the spine. Although not depicted in the figures discussed below, it is contemplated that embodiments of the present invention may be extended to provide distraction or spacing of more than two adjacent spinous processes.
Implants according to the present invention may be adapted to be inserted between a first and second spinous process at any region in the spine. Although typically implants according to the present invention may be inserted in the lumbar region, it is contemplated that it is possible to configure inserts according to the present invention for insertion into other regions such as for example, the thoracic or cervical region. In general, implants according to the invention may have varying profiles when viewed in a sagittal plane. In this regard, the implants can have varied cross-sectional shapes to conform to the varied anatomical shapes of the interspinous spaces of the spine.
Certain embodiments of implants of the invention may secure themselves in place without a supplemental attachment mechanism or fastening device attached directly to a spinous process or other portion of the spine. Alternatively, implants in accordance with the invention may be attached to one or more spinous processes or other portion of the spine, or may attach to itself in such a manner as to secure the implant between two adjacent spinal processes. By way of example, implants in accordance with the present invention may be attached to one or both spinous processes or other portion of the spine by one or more pins, screws, wires, cables, straps, surgical rope, sutures, elastic bands, or other fastening devices. Other exemplary implants, attachment mechanisms, and methods are disclosed in U.S. patent application Ser. No. 11/366,388, the entire contents of which are incorporated herein by reference. “Securing” implants between spinous processes, does not require that the implant not move at all, but rather means that the implant does not move so far away from between the spinous processes that it does not perform the function of maintaining a desired distraction distance or space between the adjacent spinous processes.
Implants in accordance with the present invention may be secured between spinous processes by methods other than using a fastening device. For example, according to certain embodiments, implants in accordance with the present invention may be secured in place with respect to spinous processes by mechanical forces resulting from the design of the implant, including the shape itself. Exemplary implants may also be secured to spinous processes, by surface modifications to portions of the implant, such as to create frictional forces or other bonds between the implant and spinous processes. Such surface modifications may include mechanical modifications to the surface (see e.g., protrusions 46 and/or knurling 47 in FIG. 2 ) and/or one or more coatings. Exemplary coatings which may be utilized include, but are not limited to, titanium plasma sprays and chrome sprays or the like. Such mechanical forces and/or surface modifications may be utilized in addition to, or in place of various other attachment methods described herein.
Referring now to FIGS. 1-3 , one exemplary embodiment of an implant 10 according to the invention is shown for creating, increasing, or maintaining distraction between adjacent spinous processes. In general, implant 10 is adapted and configured to be placed between adjacent spinous processes. For example, referring to FIGS. 24-25 , a posterior and side view, respectively, of implant 10 is shown in implanted positions between to two adjacent spinous processes 5 . As best seen in FIGS. 1-3 , implant 10 generally comprises an elongate member extending laterally along axis 12 from a first lateral end 14 to a second lateral end 16 . In one embodiment, implant 10 may be cannulated with a central cannula or opening 18 extending along axis 12 . One skilled in the art may appreciate that, in operation, cannulation 18 may facilitate advancement, travel, or delivery to an implant location over a guidewire. According to one embodiment, implant 10 may comprise a unitary body with a general barbell-like shape, and generally includes a first end portion or distraction portion 20 adjacent first end 14 , a second end portion or trailing end portion 22 adjacent second end 16 and a central support portion or saddle portion 24 disposed between the distraction and trailing end portions 20 , 22 . As best seen in FIG. 2 , support portion 24 may have a height (a) and width (d), and the implant may have an overall length (e). As best seen in FIG. 3 , in one embodiment, implant 10 has a generally circular profile or perimeter when viewed perpendicular to axis 12 . In alternate embodiments, however, implant 10 need not have a circular cross-sectional profile and the cross-sectional profile may vary along its length (e). For example, in one exemplary embodiment, distraction portion 20 may have a circular cross-sectional profile, and central support portion 24 may have a polyganol cross-sectional profile, and trailing end portion 22 may have a rectangular cross-sectional profile.
Distraction portion 20 is generally configured and dimensioned to facilitate lateral insertion between adjacent spinous processes. In one embodiment, distraction portion 20 generally comprises a frustoconical, wedged, or tapered shape widening along axis 12 from a minor diameter 26 adjacent the first end 14 to a major diameter 28 adjacent central support portion 24 . In one exemplary embodiment, the distraction portion 20 is tapered along a cone angle 30 and cone angle 30 may be between about 1 and 65 degrees. In alternate embodiments, cone angle 30 may be between about 65 and 80 degrees. In one variation, distraction portion 20 may additionally include a ramped, toothed, fluted, threaded or grooved section 32 . According to one embodiment, grooved section 32 generally comprises helical or spiral ramp peaks 36 extending from first end toward support portion 24 . Ramp peaks 36 of section 32 may have a separation sufficiently narrow to prevent the adjacent spinous process from riding within the grooves 34 defined between the peaks 36 . In this regard, the peaks 36 may be configured and dimensioned to engage or contact a portion of the spinous process bone and cause the implant 10 to advance or travel along axis 12 when implant 10 is rotated. In one variation, distraction portion 20 is configured and dimensioned such that when implant 10 is rotated about axis 12 , the adjacent spinous processes ride upon ramp peaks 36 and are distracted or separated apart as implant 10 is advanced laterally along axis 12 during implantation. The rate at which the distraction occurs may be readily controlled by a surgeon by controlling the rate of rotation of implant 10 , so that the surgeon may advance implant 10 along axis 12 as slow or as fast as desired. In this regard, implant 10 may be characterized as self-distracting, as the implant itself distracts or separates the spinous processes as it is being implanted, i.e. without requiring an additional distraction step or device.
Trailing end portion 22 adjacent second end 16 may comprise a generally frustoconical, wedged, or tapered shape narrowing along axis 12 from a major diameter 38 adjacent central support portion 24 to a minor diameter 40 adjacent the second end 16 . Those skilled in the art will appreciate that such a tapered feature may be desirable to minimize wear and trauma with adjacent soft tissue and/or bone when implant 10 is installed in a patient. In one embodiment trailing end portion 22 is generally symmetrical to distraction portion 20 with generally similar lateral length, cone angle 31 and major and minor diameters, and in some embodiments may also include a spiral ramped section or any other toothed, fluted, threaded or grooved sections, similar to distraction portion 20 . In alternate embodiments, however, the trailing end portion 22 need not be symmetrical whatsoever and may have any shape irrespective of the dimension of distraction portion 20 . For example, in at least one alternate embodiment, angle 31 could be less or greater than cone angle 30 for distraction portion 20 .
Referring to FIG. 3 , in one embodiment, a hexagonal shaped socket or indentation 42 may be provided to receive an installation or driving tool such as a hexagonal shaped driver tool. One exemplary driving tool 43 constructed according to the invention is shown in FIGS. 5-7 . In alternate embodiments, any other known rotational driving tools and engagement means may also be used, including but not limited to, a flat driver, a star shaped driver, or a threaded driver, among others. As best seen in FIG. 3 , indent 42 may be concentric with cannula 18 to facilitate insertion with a cannulated driver tool over a guidewire extending through cannula 18 and indentation 42 . In one variation, a threaded section 45 may be provided internal to indentation 42 to accommodate a threaded connection of an installation or removal tool ( FIG. 26 ) with implant 10 . In this regard, the threaded connection between a tool and the implant facilitates a laterally fixed relative connection between the implant and tool so that the implant does not dislodge from the trailing end and may efficiently transfer the rotational forces applied on the tool to the implant during installation. One skilled in the art may appreciate that the threaded connection may also facilitate the removal of implant 10 from the body of a patient should a surgeon so desire.
Central support portion 24 is provided between the distraction and trailing end portions 20 , 22 . In one embodiment, support portion 24 may have a diameter or height (a) less than the major diameters 28 , 38 of portions 20 , 22 . In this regard, when viewed from the side, as seen in FIG. 2 , implant 10 may appear to have a general H-like shape or a barbell-like shape, with the lateral sides 20 , 22 , being longitudinally spaced a distance 23 , 25 , respectively beyond central support portion 24 . In one variation, distances 23 , 25 do not need to be equal. According to one embodiment, lateral sides 20 , 22 may be spaced a distance 23 , 25 between about 1 mm and about 6 mm from the support portion 24 . In one particular embodiment, distances 23 , 25 is about 1 mm. In another embodiment, distance 23 is about 2 mm and distance 25 is about 3 mm.
As best seen in FIG. 2 , in one embodiment, the transition from the distraction portion 20 to the central support portion 24 and the transition from the central support portion 24 to trailing end portion 22 may be abrupt. In this regard, a shoulder or generally vertical wall section 44 may be formed at either end of central support portion 24 , and when implant 10 is implanted, wall sections 44 may serve to limit or block movement of the implant along axis 12 and/or dislodgement from the interspinous space. In alternate embodiments, the shoulder or transition from the central support portion 24 to the lateral end portions 20 , 22 may be gradual, curved, or ramped and may server to center the adjacent spinous process within the support portion 24 .
In one embodiment, textures, such as knurling 47 , serrations, abrasions, or other similar features may be provided along the surface of central support portion 24 to facilitate gripping or frictional contact with bone, such as the spinous process, to limit or reduce movement and/or dislodgement from the interspinous space once installed. In one variation, one or more teeth or protrusions 46 may extend laterally inward from wall sections 44 . Protrusions 46 may have a saw-tooth shape, have an angled undercut, or may have other sharpened end portions to grip and/or engage bone. In an alternate embodiment, protrusions 46 may comprise cylindrical spikes with sharp points. According to one variation, six protrusions 46 may be radially spaced about the perimeter of each wall section 44 , however, in alternate embodiments more or less protrusions may be provided as desired. In some embodiments, the geometry and spacing of the protrusions may be varied between each wall or along an individual wall section 44 . For example, a combination of saw-tooth shaped protrusions may be used in combination with spike shaped protrusions. In general, protrusions 46 may be configured and dimensioned to limit or reduce rotational, twisting, and/or lateral movement of implant 10 with respect to spinous processes when installed. In yet another embodiment, the wall sections 44 may have a star grind surface feature to limit rotational movement when installed. In other embodiments, one or more protrusions or spikes may be provided along central portion 24 and may extend radially outward to engage the spinous process.
In some embodiments, all or a portion of implant 10 may be resiliently compressible or expandable in the cranial-caudal direction such that the implant may support and or adjust to dynamic movement of the spine. For example, according to one embodiment, central support portion 24 may include a flexible bumper member to at least partially cushion the compression of adjacent spinous processes. In one variation, the bumper member may comprise a cylindrical sleeve provided to extend around the periphery of central support portion 24 . In some embodiments, the bumper member may be integrated into the support portion and in alternate embodiments the bumper member may be fit over the support portion. In one variation, the bumper member may be made from a biocompatible polyurethane, elastomer, or other similar material. In still other embodiments, implant 10 may be made from varying materials along its length, such that for example the central support portion may be made from a resilient material, such as polyurethane, elastomer or the like, and the end portions may be made from a rigid material, such as titanium or the like.
The implant itself may serve to dilate or distract the spinous processes as it is being inserted and/or after insertion. For example, in embodiments in which the implant is similar to that depicted in FIGS. 1-3 , the first end 14 of implant 10 may be initially inserted or advanced laterally between compressed adjacent spinous processes as shown in FIGS. 4-7 , for example. The supraspinous ligament may or may not be removed. In an initial pre-implantation condition, shown in FIG. 4 , the adjacent spinous processes 5 may be compressed or narrowly spaced such that the initial space or longitudinal distance 50 between the processes may be about equal to or slightly larger or smaller than distance (b) of implant 10 . During lateral insertion of the implant, one or more ramp surfaces or portions of the implant may contact one or both of the spinous processes 5 and may initially distract the processes a distance (b). As the implant is rotated, the ramp peaks 36 draw the implant 10 further between the spinous processes and, the wedged or tapered shape of the distraction portion may distract the spinous processes further apart from one another, until the implant is rotated and advanced laterally into an implanted position ( FIGS. 11-12 ) and the spinous processes are fitted into the central support portion 24 of the implant 10 . In operation, the ramp surfaces engage the adjacent spinous processes as the implant is rotated to act or perform in a cam-like manner to translate the rotational force to separate the spinous processes in the longitudinal or cranial-caudal direction as the implant is rotated. The maximum distraction of spinous processes by the implant 10 is distance (c) depicted in FIG. 6 . According to one embodiment, distance (c) is greater than distance (a) such that the spinous processes 5 may be slightly “over distracted” during installation. In this regard, one skilled in that art may appreciate that such an over distraction may facilitate enhanced tactile feedback to a surgeon during installation as the spinous processes drop into the central support portion to signify a desired lateral placement in the patient with the spinous processes positioned within the central support portion. Once the implant is implanted and after the spinous processes are fitted into the central support portion 24 , the implant may maintain the spinous processes in a distracted or spaced condition, for example where the distance (a) of the implant is greater than a pre-implantation distance between the spinous processes.
Referring to FIGS. 8-10 , another embodiment of an interspinous process implant 60 is shown. Implant 60 is similar to implant 10 described above, however, in this embodiment, the distraction portion 20 comprises a plurality of spiral grooves or flutes 62 disposed about axis 12 and extending from a narrow first end 14 toward central support portion 24 . In this embodiment, generally sharp peaks or ridges 64 may be formed along the edge of the flutes 62 and generally positioned at an angle with a plane perpendicular to axis 12 to form an inclined ramp. The ridges 64 are configured and dimensioned to engage or contact a portion of the spinous process bone and when implant 60 is rotated about axis 12 , ridges 64 generally cause the implant to advance or travel along axis 12 . In this embodiment, flutes 62 extend in a spiral direction to facilitate insertion of implant 60 in a “quarter rotation technique” such that a surgeon may insert implant 60 by rotating the device one fourth of a revolution or ninety degrees. In this regard, in one embodiment, each ridge 64 extends one fourth of the way around the periphery of distraction portion 20 . In alternate embodiments, each ridge 64 may extend one half, three fourths, or any other fractional distance around the periphery as desired to facilitate a corresponding fractional rotation insertion technique. According to one embodiment, six flutes are provided, however, in alternate embodiments, more or less spiral flutes may be used.
Referring to FIG. 8 , according to one embodiment of the invention, implant 60 may have a trailing end portion 22 with an external hexagonal shaped portion 65 instead of an internal hexagonal socket or indentation 42 as described above. Like indentation 42 , hexagonal portion 65 may be provided to engage an installation tool such as a hexagonal socket shaped driver tool. As described above with respect to implant 10 , in alternate embodiments any other known rotational driving tools and engagement means may also be used. Also similar to indentation 42 described above, in one embodiment, a threaded section 45 may be provided to accommodate a threaded connection of an installation or removal tool ( FIG. 26 ) with implant 60 . In this regard, the threaded connection between the tool and the implant facilitates a laterally fixed relative connection between the implant and tool so that the implant does not dislodge from the trailing end and may efficiently transfer the rotational forces applied on the tool to the implant during installation. One skilled in the art may appreciate that the threaded connection may also facilitate the removal of implant 60 from the body of a patient should a surgeon so desire.
Referring to FIGS. 8-10 , according to another aspect, embodiments of implants according to the invention may comprise a separate protrusion ring 66 that may be snap fitted around central support portion 24 . As best seen in FIG. 10 , protrusion ring 66 may comprise a thin C-shaped body 67 with a plurality of protrusions 68 extending laterally from one side. Protrusions 68 may be similar to protrusions 46 described above and are generally radially spaced around the perimeter of body 67 . In one variation, body 67 of ring 66 has an opening 69 to facilitate insertion over implant 60 adjacent the lateral sides of central support portion 24 with the protrusions facing laterally inward as depicted in FIGS. 8-9 . Protrusions 68 may be configured and dimensioned to limit or reduce rotational, twisting, and/or lateral movement of implant 60 with respect to spinous processes when installed. In this embodiment, ring 66 and implant 60 may be made from different materials. For example, according to one embodiment, implant 60 may be made from a radiolucent material, such as PEEK, and the ring(s) 66 may be made from a radio-opaque material, such as titanium, tantalum or any other suitable material known to those skilled in the art. In this regard, the ring(s) 66 may serve a dual purpose as a marker device recognizable under fluoroscopy as well as serving the function of limiting or reduce rotational movement when installed. In alternate embodiments, rings 66 may be provided that are entirely free of protrusions or that may sit within grooves of central support portion 24 and could function solely as marker devices without limiting movement of implant 60 relative to spinous processes when installed. For example, in one alternative embodiment, a pair of rings 66 may be provided on either lateral side of support portion 24 to provide visual markers under fluoroscopy indicating the width of support portion 24 to facilitate alignment of implant 60 with the spinous process(es) when installed. Similarly, a surgeon may visualize the central openings and/or perimeter of rings 66 under lateral fluoroscopy to gauge the lateral alignment with the spinous process(es) when installed.
Referring to FIG. 11 , another embodiment of an interspinous process implant 70 is shown. Implant 70 is similar to implants 10 , 60 described above, however, in this embodiment the distraction portion 20 comprises a plurality of laterally spaced rows of outwardly protruding teeth 72 disposed about axis 12 and spaced from a narrow first end 14 to a central support portion 24 . In this embodiment, the individual teeth 72 are radially spaced apart by a laterally extending groove or flute 74 . As can be seen in FIG. 11 , the teeth 72 nearer first end 14 are generally narrower than teeth 72 adjacent central support portion 24 . In one variation, teeth 72 extend at an angle with a plane perpendicular to axis 12 to form an inclined ramp segment. The teeth 72 are configured and dimensioned to engage or contact a portion of the spinous process bone and when implant 70 is rotated about axis 12 , teeth 72 cause the implant to advance or travel along axis 12 .
Referring to FIG. 12 , another embodiment of an interspinous process implant 80 is shown. Implant 80 is similar to implants 10 , 60 described above, however, in this embodiment, the distraction portion 20 comprises a plurality of flat facetted surfaces 82 radially disposed about axis 12 and extending angularly from a narrow first end 14 to a maximum diameter adjacent central support portion 24 . In this embodiment, sharp edges or ridges 84 may be formed along the edge of the facet surfaces 82 at an angle with a plane perpendicular to axis 12 to form an inclined ramp. In this embodiment, surfaces 82 generally extend the entire length of distraction portion 20 and ridges 84 generally form a linear path from the first end toward the central support portion. The ridges 84 are configured and dimensioned to engage or contact a portion of the spinous process bone and when implant 80 is rotated about axis 12 , ridges 84 cause the implant to advance or travel along axis 12 .
Referring to FIG. 13 , another embodiment of an interspinous process implant 90 is shown. Implant 90 is similar to implant 80 described above, however, in this embodiment the flat facetted surfaces 82 radially disposed about axis 12 are staggered, twisted or stepped angularly from a narrow first end 14 to a maximum diameter adjacent central support portion 24 . A plurality of flat surface segments 82 extend the length of distraction portion 20 and ridges 84 generally form a series of linear segments along a path from the first end toward the central support portion. Similar to implant 80 described above, the ridges 84 are configured and dimensioned to engage or contact a portion of the spinous process bone and when implant 80 is rotated about axis 12 , ridges 84 cause the implant to advance or travel along axis 12 . In this variation, a surgeon implanting the device during surgery may experience enhanced tactile feedback due to the segmented ridges. For example, during insertion a surgeon may be able to count the clicks or segment rotations to monitor the progress of the insertion.
Referring to FIG. 14 , another embodiment of an interspinous process implant 100 is shown. Implant 100 is similar to implant 10 described above, however in this embodiment the spiral ramp grooves 34 and peaks 36 are segmented or less smooth along their path. Similar to implant 10 described above, the peaks 36 are configured and dimensioned to engage or contact a portion of the spinous process bone and when implant 100 is rotated about axis 12 , peaks 36 cause the implant to advance or travel along axis 12 . In this variation, like implant 90 described above, a surgeon implanting the device during surgery may experience enhanced tactile feedback due to the segmented peaks 36 . For example, during insertion a surgeon may be able to count the clicks or segmental advancement to monitor the progress of the implant insertion.
Referring to FIGS. 15A-B , another embodiment of an interspinous process implant 110 is shown. Implant 110 is similar to implant 10 , described above, however, in this embodiment the distraction portion 20 comprises a plurality of wing members 112 disposed about axis 12 . Wing members 112 are moveable from a first position to a second position, shown in FIGS. 15A-B . During installation, wing members 112 are configured to remain in a first position below the profile of peaks 36 such that when implant 110 is implanted, the spinous processes are distracted in a similar manner as described above with respect to implant 10 . When implant 110 is installed in an implanted position, wing members 112 may be selectively moved into a second position, as shown in FIGS. 15A-B , wherein the wing members 112 generally protrude or extend radially beyond peaks 36 . In this regard, according to one embodiment, wing members 112 may have a tapered first side 114 and a generally flat second side 116 . Wings 112 may be attached to implant 110 such that when in a second position, second side 116 is generally perpendicular to support portion 24 to create a larger lateral barrier, wall, or blocking portion adjacent central support portion 24 . According to one variation, wing members 112 may be biased toward the second position by a biasing member, such as an O-ring 118 . As best seen in FIG. 15 A, in this variation, each wing member 112 may comprise a cantilevered body or pivot arm 120 pivotable about a pivot point 122 and the O-ring 118 may apply a radially inward biasing force to a tail portion 124 of one side of the wing body 120 to cause an opposite tip portion 126 of each wing member 112 to pivot about point 122 toward the second position. When implant 110 is advanced over a guidewire, the guidewire extends within the central cannula and contacts the tail portion 124 of each wing member and the tail portion 124 is forced radially outward, forcing the tip portion 126 to pivot inward toward the first position. One skilled in the art may appreciate that utilizing such a configuration, the wing members 112 may remain in a first position to facilitate implantation over a guidewire and then once the guidewire is removed, the wing members may spring or bias outwards to the second position to form a larger lateral barrier, wall, or blocking portion adjacent central support portion to limit or reduce the possibility of lateral migration of implant 110 in the body. In alternate embodiments, alternative mechanisms may be utilized to achieve the aforementioned result. For example, in one alternative a torsion spring may be positioned adjacent pivot point 122 to bias the wing members 112 toward the second position. Also, in alternative embodiments, the shapes and dimensions of wing members may be altered as desired.
Kits having at least one implant such as those depicted in FIGS. 11-15 , may include various sizes of implants having varying heights (a), widths (d), and overall lengths (e), for example having variations with incremental distances. In one embodiment, a system or kit may be provided that has implants having heights (a) between about 6 mm to about 22 mm. For example, in one variation implants having heights (a) of 8 mm, 10 mm, 12 mm, 14 mm, 16 mm, 18 mm, and 20 mm may be provided. In another variation, a system or kit may be provided that has implants having widths (d) between about 6 mm to about 18 mm. For example, in one variation implants having widths (d) of 8 mm, 12 mm, and 16 mm may be provided. In yet another variation, a system or kit may be provided that has implants having overall lengths (e) between about 20 mm and about 60 mm. For example, in one variation implants having overall lengths (e) of 25 mm and 50 mm may be provided.
Material
Implants in accordance with the present invention may be made of one or more materials suitable for implantation into the spine of a mammalian patient. Materials in accordance with the present invention may be biocompatible with a mammalian patient and/or may have one or more surface coatings or treatments that allow the spacers to be biocompatible. Materials in accordance with the present invention may include one or more materials having sufficient load capability and/or strength to maintain the desired spacing or distraction between spinous processes. Depending on the design employed, certain embodiments may have components or portions made of a material having certain flexibility, as desired for the particular application. Additionally, the materials of the present invention may be made of one or more materials that maintain their composition and shape for as long a time as possible without degrading or decomposing or changing shape, such that replacement of the implant is avoided.
Suitable materials for use in accordance with the present invention would be known to those skilled in the art. Non-limiting examples include one or more materials selected from medical grade metals, such as titanium or stainless steel, biocompatible polymers, such as polyetheretherketone (PEEK), ceramics, deformable materials, bone, allograft, demineralized or partially demineralized bone, allograft ligament, and polyurethane (for example, for portions of the insert where cushioning is desired). Similarly, any fastening devices may be made of materials having one or more of the properties set forth with respect to the implant itself. For example, screws or pins may include titanium and straps may include polyethylene. In some embodiments, primarily radiolucent material may be used. In this regard, radio-opaque material or markers may be used in combination with the radiolucent material to facilitate implantation. Exemplary radio-opaque material includes but is not limited to titanium alloys, tantalum or other known radio-opaque marker material. As indicated above, implants in accordance with the present invention may have one or more portions that may have modified surfaces, surface coatings, and/or attachments to the surface, which may assist in maintaining the spacer in a desired position, for example by friction. Suitable surface modifications, coatings, and attachment materials would be known to those skilled in the art, taking into consideration the purpose for such modification, coating, and/or attachment.
Methods for Treating Stenosis and Methods of Inserting an Implant
Methods are provided for treating spinal stenosis. Methods are also provided for inserting an implant. These methods may include implanting a device to create, increase, or maintain a desired amount of distraction, space, or distance between adjacent first and second spinous processes. The adjacent first and second spinal processes may be accessed by various methods known by practitioners skilled in the art, for example, by accessing the spinous processes from at least one lateral side/unilateral, bilateral, or midline posterior approach.
Certain methods of the present invention include creating an incision in a patient to be treated, dilating any interspinous ligaments in a position in which the implant is to be placed in the patient, sizing the space between adjacent spinous processes (for example using trials), and inserting an implant of the appropriate size between the adjacent spinous processes. Methods of the present invention may include securing the implant to one or more of the spinous processes, to one or more other portions of the patient's spine, and/or to itself such that the implant maintains its position between the spinous processes.
Methods of the present invention may include dilating or distracting the spinous processes apart from one another before sizing and/or before inserting the implant. Methods may vary depending on which implant is being inserted into a patient. For example, certain implants may require distracting the spinous processes apart before inserting the implant, while other implants may themselves dilate or distract the spinous processes while inserting the implant. In embodiments where the implants themselves dilate or distract the spinous process, the implant may have, for example, a predetermined shape to dilate, distract, or otherwise move or separate apart adjacent spinous processes such as a cam or cam-like profile, it may have a distraction device that is deployed, and/or it may have a tapered expander to distract an opening between the adjacent spinous processes or other features to facilitate distraction of the adjacent spinous processes.
According to certain embodiments, spacers may be placed between the spinous processes anterior to the supraspinous ligament, avoiding the nerves in the spinal canal. The procedure may be performed under local anesthesia. For surgical procedures, in which an implant is being inserted into the lumbar region, the patient may be placed in the right lateral decubitus position with the lumbar spine flexed or in another flexed position. According to one method, a surgeon may desire to use fluoroscopy to align in parallel the adjacent vertebral bodies corresponding to the adjacent spinous processes to gauge the desired distraction distance.
According to certain embodiments, one or more probes may be used to locate the space between the spinous processes. Depending on the design of the spacer to be inserted, the space may be widened, for example with a dilator before inserting the implant.
Referring to FIGS. 16-25 , one embodiment of a surgical method according to the invention for implanting an implant 10 in the spine is disclosed. According to this embodiment, the adjacent first and second spinal processes 5 may be accessed from one lateral side through a minimally invasive procedure. In this regard, according to certain methods of the invention, a unilateral approach may be used to install implant 10 without removal of the supraspinous ligament. In this method, as shown in FIG. 16 , a guide wire 202 , such as a K wire, is inserted laterally through the skin and into the interspinous space 204 . According to one method, a working portal may be created concentric to the guidewire 202 , as shown in FIGS. 17-18 , by inserting a series of sequentially larger diameter tubes 206 , 208 , 210 , 212 , 214 to dilate the tissue surrounding guidewire 202 . Referring to FIG. 19 , once a dilating tube having a sufficiently large inner diameter to accommodate implant 10 is positioned about guidewire 202 , the smaller diameter tubes 206 , 208 , 210 , 212 may be withdrawn, leaving the guidewire 202 and the outer tube 214 . Referring to FIG. 20 , one or more trials 215 may then be inserted to appropriately size the interspinous space 204 and the trials 215 may also be utilized to dilate interspinous ligaments. In one exemplary embodiment, a generally cannulated cylindrical trial 215 , shown in FIG. 20 , may be utilized to size the space between adjacent processes 5 . Referring to FIG. 21 , an alternate embodiment of a trial 216 that may be used is shown which may comprise a ramped tip portion 217 adjacent its distal end and multiple longitudinal indentations or markings 218 on at least a portion of central portion 219 and may provide visual indication when viewed under fluoroscopy of the width of the spinous processes and facilitate the surgeon's selection of an appropriately sized implant. Similarly, the appropriate diameter of central portion 219 of trial 216 may be selected to gauge the amount of distraction desired. In this regard, the spacing of the spinous processes may be viewed under fluoroscopy to facilitate the surgeon's selection of an appropriately sized implant. Finally, an implant of the appropriate size may be inserted between the adjacent spinous processes.
Referring to FIGS. 22-23 , one exemplary embodiment of a method of installing implant 10 is shown. Implant 10 is advanced over guidewire 202 through cannulation 18 to the interspinous space 204 . During lateral insertion of the implant between the spinous processes, one or more ramp surfaces or portions of the implant may contact one or both of the spinous processes 5 and may initially distract the processes. Implant 10 may be rotated to further advance implant 10 between the spinous processes and, the wedged or tapered shape of the distraction portion 20 may distract the spinous processes further apart from one another, until the implant is rotated and advanced laterally into an implanted position ( FIGS. 22-25 ) with the distraction portion 20 positioned on the contralateral side of the spinous processes and the spinous processes are fitted into the central support portion 24 of the implant 10 . Referring to FIGS. 24-25 , once implant 10 is installed, the guidewire may be removed through the cannulation leaving the implant 10 in the interspinous space.
Referring to FIG. 26 , one embodiment of an implant removal tool 260 is shown. Removal tool 260 generally comprises an elongate cannulated body 262 with an externally threaded distal tip 264 rotatably connected to thumb barrel member 266 . Distal tip 264 is generally configured and dimensioned to engage threaded section 45 , described above, of an implant to accommodate a threaded connection of removal tool 260 and an implant. In this regard, a surgeon may rotate distal tip 264 by rotating thumb barrel 266 to establish a threaded connection between the tool and the implant. As described above, such a threaded connection facilitates a laterally fixed relative connection between the implant and tool so that the implant does not dislodge from the trailing end and a surgeon may remove or back out the implant from the body if desired.
While the invention herein disclosed has been described by means of specific embodiments and applications thereof, numerous modifications and variations can be made thereto by those skilled in the art without departing from the scope of the invention. | In an exemplary embodiment, the present invention discloses interspinous process spacers that can be placed between adjacent spinous processes for minimally invasive surgical treatment of a spinal disease or defect. In particular, the present invention, in one embodiment, discloses an interspinous process spacer having a distraction end, a central support portion, and a trailing end. Also disclosed in the present invention are systems and kits including such implants, methods of inserting such implants, and methods of alleviating pain or discomfort associated with a spinal column disease or defect. | 0 |
BACKGROUND OF THE INVENTION
[0001] This invention relates to a pressure-releasing valve, particularly to one capable of reserving air pressure in the condenser of an automobile engine when the engine is changing from a condition of accelerating and increasing pressure to a condition of running idly and releasing pressure, so that when accelerating again, the engine can be supplied with air pressure in time to run smoothly, having functions of economizing oil and ensuring safety.
[0002] A conventional air-conditioning system of an automobile engine, as shown in FIG. 1, includes an air sucking tube (A), a pressure increasing member (B), a condenser (C), an engine (D) and a pressure releasing valve (E) combined together.
[0003] The air sucking tube (A) is connected to the pressure increasing member (B), the pressure increasing member (B) is connected to the condenser (C) through an air tube (BO), and the condenser (C) is connected to the engine (D) through an air tube (CO). The pressure- releasing valve (E) is provided between the engine (D) and the air sucking tube (A) as well as the air tube (BO), and connected to the engine (D) through a small air tube (DO).
[0004] The pressure-releasing valve (E), as shown in FIGS. 2 and 3, includes a valve body (EO) with two outlets (E 1 ) and (E 2 ), and a valve (E 3 ) inside able to close up the outlets (E 1 ), (E 2 ) at the same time. The valve (E 3 ) is provided inside with a spring (E 4 ) and a spring chamber (E 5 ) with an inlet (E 6 ). Thus, when the engine (D) is changing from a condition of accelerating and increasing pressure to a condition of running idly and releasing pressure, it will produce a proper sucking force to suck open the valve (E 3 ) through the small air tube (DO), as shown in FIG. 2, letting the air sucked by the air sucking tube (A) circulate in a direction indicated by the arrow (R 1 ) in FIG. 1. On the contrary, when accelerating, the engine (D) no longer has a sucking force, so the valve (E 3 ) is closed up by the resiliency of the spring (B 4 ), as shown in FIG. 3, letting the air run in a direction indicated by the arrow (R 2 ) in FIG. 1 and then get into the engine (D) to cool it down.
[0005] However, when such a conventional pressure-releasing valve (E) is in a condition of oil return, it will completely release the air out so no air pressure remains inside the condenser (C). Under such condition, it may take a little time (less than a second) to let the condenser (C) filled up with air, which then gets in the engine (D) to enable the engine (D) to work smoothly in case of gear shifting or accelerating. Such breaking off of air pressure caused in the period of shifting gears or stepping on an accelerator will delay accelerating or starting the engine, resulting in danger in driving and wasting energy.
[0006] Although delay time is only a fraction of s second, there are many times of shifting gears, consumed energy may be not to be ignored.
[0007] Besides, when a car is running with high speed and if there happens a delay in accelerating, a driver may make wrong judgment to cause danger.
SUMMARY OF THE INVENTION
[0008] The objective of the invention is to offer an engine capable to keep the condenser of an automobile engine filled up with air pressure when the engine is changing from a condition of accelerating to a condition of running idly, so that the engine can be supplied with air pressure in time to run smoothly, having functions of saving oil and ensuring safety in driving when accelerating again.
[0009] The feature of the invention is that a pressure- reserving chamber is provided inside a pressure- releasing valve. The pressure-reserving chamber can retain a proper amount of air pressure when the engine is changing from a condition of accelerating and increasing pressure to a condition of running idly and releasing pressure, so that when the engine starts accelerating again, air pressure can be supplied in time for the engine to run smoothly.
BRIEF DESCRIPTION OF DRAWINGS
[0010] This invention will be better understood by referring to the accompanying drawings, wherein:
[0011] [0011]FIG. 1 is a cross-sectional view of a conventional air conditioning system of an automobile engine;
[0012] [0012]FIG. 2 is a cross-sectional view of a conventional pressure-releasing valve in a condition of oil return and pressure releasing;
[0013] [0013]FIG. 3 is a cross-sectional view of the conventional pressure-releasing valve in a condition of accelerating and increasing pressure;
[0014] [0014]FIG. 4 is a cross-sectional view of an air conditioning system in the present invention;
[0015] [0015]FIG. 5 is an exploded perspective view of a pressure-releasing valve in the present invention;
[0016] [0016]FIG. 6 is side cross-sectional view of the pressure-releasing valve in the present invention;
[0017] [0017]FIG. 7 is a cross-sectional view of the pressure- releasing valve in a condition of accelerating and increasing pressure in the present invention;
[0018] [0018]FIG. 8 is a cross-sectional view of the pressure releasing valve in a condition of oil return and releasing pressure and idly running in the present invention;
[0019] [0019]FIG. 9 is a cross-sectional view of the pressure- releasing valve in a condition of the engine running idly in the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0020] A preferred embodiment of a pressure releasing valve in the present invention, as shown in FIG. 4, includes an air tube connecter 2 , a left cover 4 , an air chamber holder 5 , a casing 6 and a right cover 8 as main components combined together.
[0021] The air tube connecter 2 is crewed with a nut 20 on the outer surface and formed with male threads around the right end to be engaged with a female threaded hole 40 of the left cover 4 . The air tube connecter 2 is connected to a pressure return tube 12 and fitted with an O-shaped gasket 21 to prevent leaking.
[0022] The left cover 4 is formed with a chamber 420 for receiving a left and a right stop member 41 and 45 and a spring 42 , having a plurality of bolt holes around an outer side for bolts 44 to pass therethrough and be fixed with a left casing 60 . Then, the left and right stop members 41 and 45 respectively having a central hole 410 , 450 are provided on the opposite sides of the spring 42 , with the central hole 410 of the left stop member 41 aligned with the central hole 22 of the air tube connecter 2 . Thus, when the engine is in a condition of oil return, the air in the chamber 420 of the left cover 4 will be pumped out through the pressure return tube 12 , and the spring 42 will be pressed by the right stop member 45 which has its central hole 450 inserted through by a small rod 50 of the air chamber holder 5 .
[0023] In addition, a first valve strip 51 is tightly sandwiched by the right stop member 45 and a gasket 52 of the air chamber holder 5 , having a plurality of small holes 510 formed around its circumferential edge for the bolts 44 to be inserted therethrough to make the first valve strip 5 fixedly sandwiched by the left cover 4 and a left casing 60 , letting the air in the chamber 420 come in or go out through only one opening.
[0024] The air chamber holder 5 is provided with a lengthwise through hole 53 and a lateral hole 54 . After the air chamber holder 5 is fitted around with a sleeve 55 and an O-shaped ring 56 , it is fitted with two leakage preventive rings 57 and 58 between opposite opening of the lengthwise through hole 53 . Then, the O-shaped ring 56 and the leakage preventive rings 57 , 58 are positioned in the central hole 600 inside the left casing 60 , which is for receiving the air chamber holder 5 .
[0025] The casing 6 consists of a left casing 60 , an intermediate casing 61 and a right casing 62 . These three casings 60 , 61 and 62 are respectively provided with an air intake passage 63 communicating with one another. The left casing 60 further has two air releasing passages 601 and 602 , with the air releasing passage 601 positioned at the right side of the first valve strip 51 to keep the air in the right side chamber 603 of a first valve sheet 51 in a circulating condition and let the first valve sheet 51 operate smoothly. The air releasing passage 602 can communicate with the lengthwise hole 53 of the air chamber holder 5 when accelerating and increasing pressure so as to pump out the air in the pressure reserving chamber 64 , but during oil return and releasing pressure, the air releasing passage 602 can not communicate with the lengthwise hole 53 , as shown in FIGS. 8 and 9. Besides, the left casing 60 is bored with a plurality of boltholes 604 for long bolts 605 to pass through and combine three casings 60 , 61 and 62 together.
[0026] Further, a second valve sheet 65 is sandwiched between the left casing 60 and the intermediate casing 61 , with a pressure-reserving chamber 64 formed between the second valve sheet 65 and the left casing 60 . The second valve sheet 65 is formed with a central hole 650 for a shaft rod 7 to be inserted therein, and a plurality of small holes 651 around the circumferential edge for the long bolts 605 to be inserted therethrough. The shaft rod 7 is provided between the intermediate casing 61 and the right casing 62 , having its left end inserted through the second valve sheet 65 and then fixed by a gasket 70 . Then, a left stop member 71 and a spring 72 are orderly provided on the right side of the second valve sheet 65 , with the spring 72 fitted in the spring holder 610 of the intermediate casing 61 . The shaft rod 7 is further fitted around with a sleeve 73 to be positioned in the central hole 611 of the intermediate casing 61 , having its right end combined with a right stop member 74 and secured together by a bolt 75 . The right stop member 74 is fixed in the central hole 620 of the right casing 62 and pushed against by a leakage preventive ring 621 . The intermediate casing 61 has an air releasing passage 614 to let the air of the spring holder 613 communicate with external air, and a plurality of bolt holes 612 for the long bolts 605 to be screwed therethrough. Then, the right casing 62 is provided with a circulation tube opening 622 to be connected with an air tube 10 .
[0027] The right cover 8 is formed with a connecter 80 for receiving an air tube 11 , and provided with a circular rim 81 to be mounted around with a ring 82 fixed with the right casing 62 by means of bolts 820 , with a O-shaped gasket 623 closely fitted between the right cover 8 and the right casing 62 to prevent leaking.
[0028] When the engine of this invention is in a condition of accelerating and increasing pressure, as shown in FIG. 7, the cool air pumped in will move in a direction indicated by the arrow R 2 in FIG. 4 and the pressure-releasing valve 1 is in a silent condition.
[0029] When the accelerator is released, and the engine gives rise to oil return and pressure releasing, as shown in FIG. 8, the air of the air-conditioning system will circulate in a direction indicated by the arrow R 1 in FIG. 4 and get into the pressure reserving chamber 64 through the air chamber 83 of the right cover 62 , through the air intake passage 63 , and through the lengthwise through hole 53 and the lateral hole 54 of the air chamber holder 5 . At this time, the air pressure in the pressure reserving chamber 64 is large enough (more than 0.2 kg) to press the second valve 65 and move the right stop member 74 of the shaft rod 7 to make the central hole 620 of the right casing 62 opened so as to let the air get out of the air tube 10 through the central hole 620 .
[0030] In case the engine runs more and more slowly to idly, it will produce a sucking force toward the chamber 420 through the pressure return tube 12 and force the first valve sheet 51 to move forward together with the air chamber holder 5 . Thus, the air intake passage 63 can communicate with the pressure reserving chamber 64 through the air chamber holder 5 , and at this time, the central hole 620 of the right casing 62 is closed, because the air pressure in the pressure reserving chamber 64 is less than 0.2 kg, as shown in FIG. 9. The remaining air in the pressure reserving chamber 64 lets the condenser keep a certain amount of air pressure inside, therefore every time the engine accelerates and increases pressure, as shown in FIG. 7, the condenser can immediately supply the engine with air to enable the engine run smoothly all the time, having functions of saving oil and elevating efficiency of an engine.
[0031] While the preferred embodiment of the invention has been described above, it will be recognized and understood that various modifications may be made therein and the appended claims are intended to cover all such modifications that may fall within the spirit and scope of the invention. | A pressure releasing valve capable of reserving air pressure is formed with a pressure reserving chamber to retain a proper amount of air pressure in the pressure releasing valve when the engine is changing from an accelerating and increasing pressure condition to a condition of running idly and releasing pressure, so that when the engine accelerates and increases pressure again, air of the condenser can be continually supplied for the engine to let it run comparatively smoothly in accelerating, not only economizing energy but ensuring safety as well. | 5 |
FIELD OF INVENTION
The present invention relates to an image processing device, image processing method, and program, especially to an image processing device, image processing method, and program for reconstructing a 3D shape from input 2D image.
BACKGROUND OF INVENTION
To measure 3D shapes of dynamic scenes or objects, such as human facial expressions or body motions, speed, density and accuracy of measurement are crucial. Since passive stereo techniques have difficulties in reconstructing textureless surfaces densely and accurately, active 3D measurement techniques, especially those using high-speed structured light systems, have been extensively studied in recent years for capturing dynamic scenes.
Since a structured light system reconstructs 3D shape by projecting single or multiple patterns on a scene by a projector and capturing the scene by a camera, correspondences between feature points of projected pattern and captured scene is required. Many structured light systems temporally encode positional information of a projector's pixel into multiple patterns. Recently, structured light systems that can capture a dynamic scene by reducing the required number of patterns and increasing pattern speed have been proposed. These systems assume that there is little motion in a scene while a sufficient number of patterns for decoding are projected. In addition, the design of high-speed synchronization system is also an issue.
On the other hand, ‘one-shot’ structured light techniques using only single images in which positional information of the projectors' pixels are embedded into spatial patterns of the projected images have also been studied. Although the techniques can resolve the issues of rapid motions and synchronization, they typically use patterns of complex intensities or colors to encode positional information into local areas. Because of the complex patterns, they often require assumptions of smooth surface or reflectance, and the image processing tends to be difficult and to be low resolution. If the assumptions do not hold, the decoding process of the patterns may be easily affected and leads to unstable reconstruction.
As for a commonly used constraint to determine correspondences for structured light system, there is epipolar constraint. However, in case of a number of feature point is large or there are several feature points on a epipolar line because of a condition of arrangement of feature points, correspondences cannot be uniquely determined.
Shape reconstruction techniques with a structured light system, which encode positional information of a projector into temporal or spatial changes in a projected pattern, have been largely investigated. A technique using only temporal changes is easy to implement, so it has commonly been used thus far [Non Patent Literature 1].
Techniques using only spatial encoding of a pattern allow scanning with only a single-frame image (a.k.a. one-shot scan) [Non Patent Literature 2-4].
Non patent literature 5 shows reduced number of patterns by using both of temporal change and spatial change.
Although it does not strictly involve a structured light system, methods of shape reconstruction to include movement by spatiotemporal stereo matching are proposed [Non Patent Literature 6 and 7].
On the other hand, a technique allowing dense shape reconstruction based on a single image using a simple pattern, i.e. a set of stripes is proposed [Non Patent Literature 8].
[Non Patent Literature 1] S. Inokuchi, K. Sato, and F. Matsuda. Range imaging system for 3-D object recognition. In ICPR, pages 806-808, 1984.2
[Non Patent Literature 2] C. Je, S. W. Lee, And R.-H. Park. High-Contrast Color-stripe pattern for rapid structured-light range imaging. In ECCV, volume1, pages 95-107, 2004. 2, 5.
[Non Patent Literature 3] J. Pan, P. S. Huang, and F.-P. Chiang. Color-coded binary fringe projection technique for 3-d shape measurement. Optical Engineering, 44 (2): 23606-23615, 2005.
[Non Patent Literature 4] J. Salvi, J. Batlle, and E. M. Mouaddib. A robust-coded pattern projection for dynamic 3d scene measurement. Pattern Recognition, 19(11): 1055-1065, 1998.
[Non Patent Literature 5] S. Rusinkeiwicz: “Real-time 3D model acquisition”, ACM SIGGRAPH, pp. 438-446 (2002).
[Non Patent Literature 6] O. Hall-Holt and S. Rusinkiewicz. Stripe boundary codes for real-time structured-light range scanning of moving objects. In ICCV, volume 2, pages 359-366, 2001.
[Non Patent Literature 7] L. Zhang, N. Snavely, B. Curless, and S. M. Seitz. Spacetime faces: High-resolution capture for modeling and animation. In ACM Annual Conference on Computer Graphics, pages 548-558, August 2004. 2
[Non Patent Literature 8] T. P. Koninckx and L. V. Gool. Real-time range acquisition by adaptive structured light. IEEE Trans. on PAMI, 28(3):432-445, March 2006.
SUMMARY OF THE INVENTION
Technical Problem
However, backgrounds of these techniques as seen above have following difficulties.
In terms of the technique described in [Non Patent Literature 1], since the technique uses multiple patterns necessary for decoding, it requires special attention to be applied to high-speed capturing.
In terms of the technique described in [Non Patent Literature 2-4], they encode positional information into a spatial pattern, and thus, there remains a problem for low resolution on the pattern and 3D reconstruction. In addition, because of requirement of unique codification in local area, patterns are usually become complex and image processing for detecting patter are also complex. Because of aforementioned reason, the decoding process of the patterns may be easily affected and leads to ambiguities near depth or color discontinuities.
In terms of the technique described in [Non Patent Literature 5], the technique is basically limited in that the scene must be static while multiple patterns are projected. In addition, since the method proposes a solution only for slow motion of rigid body object by aligning the reconstructed shape with respect to a rigid body constraint, it cannot be applied for non-rigid object with motion, such as human facial motion or body motion.
In terms of the technique described in [Non Patent Literature 6-7], with these techniques, a projector is only used to provide a texture that changes over time for a pair of stereo cameras and produce high-quality depth reconstructions. Since all the techniques assume continuous motion of an object, there remains an open problem that correct shapes cannot be reconstructed if there is a fast motion which makes a discontinuity in spatio-temporal space.
In addition, there are common problems for [Non Patent Literature 5-7], such as system needs extremely fast synchronization to adapt fast motion of object and/or processing cost tends to relatively high.
In terms of the technique described in [Non Patent Literature 8], Euclidean shape reconstruction was achieved by combining local shape reconstruction from dense stripes pattern (repetitive line pattern) and global positional registration by detecting supplemental sparse line pattern. Therefore, it remains an open problem that correct shapes cannot be reconstructed if it fails either detecting sparse line pattern or extracting stripe pattern.
The present invention is published by considering the aforementioned problems. The main target of the invention is to provide an image processing apparatus, image processing method, and program to achieve dense 3D shape reconstruction with robust image processing method.
Solution to Problem
In this invention, by using the technique which uses coplanar constraint derived from multiple images projected by a line laser to reconstruct a scene or shape, 3D shape is reconstructed from coplanar constraints of intersection points between two types of line patterns projected by a projector. Such a method can be found in, for example, “Shape Reconstruction from Cast Shadows using Coplanarities and Metric Constraints” ACCV, Part II, LINCS 4843, PP. 847-857, 2007.
The present invention is an image processing apparatus comprising:
a light projection unit using a light source,
said light source projecting a plane shaped light pattern, projecting a first pattern and a second pattern to an object, said first pattern being arranged to fulfill a first common constraint, and said second pattern being arranged to make an intersection with said first pattern and fulfill a second common constraint;
an image capturing unit obtaining a 2D image by capturing a reflected pattern on said object,
said reflected pattern being a projection of said plane shaped light pattern; and
an image processing unit reconstructing a 3D shape of said object using said 2D image,
wherein said image processing unit comprising:
a first calculation unit configured to obtain an intersection point between a first captured pattern and a second captured pattern on said 2D image,
said first captured pattern being observed as a reflected pattern of said first pattern, and said second captured pattern being observed as a reflected pattern of said second pattern; and
a second calculation unit configured to calculate a first solution of a first undetermined plane and a second undetermined plane by using a constraint, said first common constraint, said second common constraint, and a first relative positional information;
said first solution including a degree of freedom, said first undetermined plane being a plane including said first captured pattern, said second undetermined plane being a plane including said second captured pattern, said constraint being that said intersection point is included by said first undetermined plane and said second undetermined plane, and said first relative positional information being a relative positional information between said light projection unit and said image capturing unit.
Advantageous Effects of Invention
In our invention, by using a simple grid pattern consisting of a number of lines which can be distinguished only vertical or horizontal line, 3D reconstruction are achieved by using intersection points of those lines as feature points. By using such feature points, since relationship between feature points are obtained from connectivity of vertical and horizontal lines, 3D shape which are consistent under intersection of vertical and horizontal lines can be reconstructed as solution set of parameters by applying the shape from coplanarity constraint. In addition, a degree of freedom is one when grid pattern is known, and thus, it can be determined quickly by one dimensional search. Therefore, 3D shape of dynamic scene or moving objects can be densely reconstructed.
In addition, it has the advantages of the shape not necessarily needing to be globally smooth as long as the local connectivity of the grid points can be extracted and thus allows the shape to be restored even when there are abrupt changes in depth due to an occlusion or in color due to texture. Moreover, since only a discrimination of vertical and horizontal line is required for reconstruction, there remain only a small problem on image processing.
BRIEF DESCRIPTION OF THE DRAWINGS
[ FIG. 1 ] (A) illustrates the image processing apparatus of the invention and (B) illustrates the image processing method of the invention.
[ FIG. 2 ] The figure illustrates the image processing apparatus of the invention.
[ FIG. 3 ] The figure illustrates the image processing method of the invention and the plane relating to the plane of the pattern irradiated by projector.
[ FIG. 4 ] The figure illustrates the image processing method of the invention and the plane relating to the plane of the pattern irradiated by projector.
[ FIG. 5 ] The figure illustrates the image processing method of the invention and set of planes of the pattern irradiated by projector.
[ FIG. 6 ] The figure illustrates the image processing method of the invention and the method of 3D shape reconstruction.
[ FIG. 7 ] The figure illustrates the image processing method of the invention and, (A) illustrates the image of irradiated pattern and (B) illustrates the extracted linear pattern.
[ FIG. 8 ] The figure illustrates the image processing method of the invention and, (A) illustrates the pattern where both sparse and dense pattern are used for vertical direction, (B) illustrates detected sparse pattern and (C) illustrates detected dense pattern.
[ FIG. 9 ] The figure illustrates the image processing method of the invention and, (A) illustrates the input images by regular pattern, (B) illustrates the input images by random pattern and (C) illustrates results of image processing using random pattern.
[ FIG. 10 ] The figure illustrates the image processing method of the invention, and the graph illustrates the error to noise ratio.
[ FIG. 11 ] The figure illustrates the image processing method of the invention and the captured image of processing apparatus during scanning.
[ FIG. 12 ] The figure illustrates the image processing method of the invention and, (A) and (B) illustrate the target object, (C), (D) and (E) illustrates the result of reconstitution, and (F) illustrates the target object, (G) and (H) illustrates the result of reconstitution and (I) illustrates the texture-mapped model.
[ FIG. 13 ] The figure illustrates the image processing method of the invention and (A) illustrates the captured object, (B) and (C) illustrates input image and (D) illustrates detected horizontal pattern, (E) illustrates detected dense vertical pattern, (F) illustrates detected sparse vertical pattern, (G) illustrates dense intersection of pattern, (H) illustrates sparse intersection of pattern, (I) illustrates reconstruction of dense pattern, (J) illustrates reconstruction of sparse pattern, (K) illustrates integration results and (L)-(N) illustrate both of reconstructed shape and ground truth.
[ FIG. 14 ] The figure illustrates the image processing method of the invention and (A) illustrates the input scene, (B) illustrates input image and (C)-(E) illustrates example of reconstruction of three 3 types of facial expression.
BRIEF DESCRIPTION OF THE DRAWINGS
10 Image processing apparatus
12 Projector
14 Camera
16 Image processing method
18 Object
20 Controller unit
22 Input unit
24 Storage unit
26 Display unit
28 Manipulation unit
30 Image processing unit
32 Intersection obtaining unit
34 The first solution calculation unit
36 The second solution calculation unit
38 3D shape reconstruction unit
DETAILED DESCRIPTION OF EMBODIMENTS
<First Embodiment: Configuration of the Image Processing Apparatus>
Configuration of the image processing apparatus regarding to the embodiment of the present invention will now be explained referring to FIG. 1 .
FIG. 1(A) is an example of configuration of the image processing unit 10 and FIG. 1(B) shows a configuration of the image processing method 16
Referring to FIG. 1(A) , the image processing apparatus 10 according to the embodiment mainly includes projector 12 for light projection method, camera 14 for image capturing method and, for example, a personal computer for the image processing method 16 .
Projector 12 has a function to project a light with predetermined pattern to a target object 18 and as for an actual device, for example, video projector can be considered. It is also possible to configure or align line-laser projectors as for an actual devise. Otherwise, using prism or beam-splitter to split laser light source into multiple directions is also possible. Projector 12 projects two types of patterns, such as vertical and horizontal directional pattern to a target object. Here, vertical pattern (the first pattern) and horizontal pattern (the second pattern) are perpendicular to each other and those are distinguished by for example color information. In this invention, only two patterns' discrimination is required, selection of two colors from RGB (red, green and blue) is one solution. Further, different wave length for vertical and horizontal pattern is enough for the invention, invisible light source (e.g., infrared) can be used. In addition, to use specific wave length for light source, high precision discrimination can be achieved by capturing with a narrow band path filter. Further, it is not required to be perpendicular between vertical and horizontal patterns, but just making intersection is enough. Instead of color, width of pattern or angle of pattern can be used to distinguish two kinds of pattern. It is only required that vertical and horizontal lines are extracted from image, therefore, projecting a grid based pattern and extracting lines from an image or projecting a band where width is wider than a line and extracting boundary of the band are also sufficient. It is advantageous to use boundary of a band because it can extract two times pattern of a number of bands. Further, projecting checker board pattern and extracting a boundary of the pattern is also sufficient.
Camera 14 has a function to capture a reflected light from an object by projecting a light from projector 12 and as for an actual device, for example, CCD image sensor, solid imaging device, etc. can be used. 2D image is captured by camera 14 and by performing image process 16 on data based on 2D image, 3D shape of object 18 is reconstructed. Here, relative position of camera 14 and projector 12 can be either calibrated before scan, calibrated online, or self-calibrated, and can be assumed to be known.
Configuration of the image processing method 16 for 3D shape reconstruction from 2D image will now be explained referring to FIG. 1(B) .
An image processing apparatus 16 according to the embodiment mainly includes an image processing unit 30 , a control unit 20 , an input unit 22 , a storage unit 24 , a display unit 26 , and a manipulation unit 28 . The schematic function of the image processing apparatus 16 is to processing 2D image so as to reconstruct and output 3D shape. In addition, an implemented image processing apparatus 16 may be constructed with a computer such as a personal computer where an application (program) of executing a predetermined function is installed or a dedicated image-processing apparatus of executing a predetermined function. In addition, units constituting the image processing apparatus 16 are electrically connected to each other via a bus.
The image processing unit 30 is a unit that mainly performs an image processing function. The image processing unit 30 includes a intersection obtaining unit 32 , the first solution calculation unit 34 , the second solution calculation unit 35 , and 3D shape reconstruction unit 38 .
The intersection obtaining unit 32 (the first solution calculation unit) is a unit that obtain intersection of vertical and horizontal patterns which are detected from 2D image captured by camera 14 .
The first solution calculation unit 34 (the second calculation unit) is a unit that calculate the first solution including a degree of freedom by using a constraint that aforementioned patterns share intersection point, a constraint that plane including pattern pass through the predetermined common line and constraint obtained from the relative positional relationship between camera 14 and projector 12 .
The second solution calculation unit 36 (the third calculation unit) is a unit that calculate the second solution by eliminating a degree of freedom of the first solution calculated by the first solution calculation unit.
3D shape reconstruction unit 38 is a unit that reconstructs the 3D shape of captured object using the calculated second solution.
Detail explanations of each unit of aforementioned image processing unit are described as image processing method in the followings.
The control unit 20 is a unit that controls operations of the entire units of the image processing apparatus 16 (the image processing unit 30 , the input unit 22 , the storage unit 24 , and the display unit 26 ).
The input unit 22 is a unit where information is externally input to the image processing apparatus 16 . In the embodiment, a movie or an image consist of 2-D image is input from the input unit 16 .
The storage unit 24 is a fixed storage disk such as a HDD (hard disk drive), a detachable storage disk such as a CD (compact Disc) or DVD (digital versatile disk), a fixed or detachable semiconductor device, or the like. In the embodiment, a plurality of the 2-D image before the process and 3-D shape reconstructed from the 2-D image are stored in the storage unit 18 .
In addition, a program for executing the image processing method described later is stored in the storage unit 24 . The program allows functions of the aforementioned units to be executed by user's manipulation of the manipulation unit 28 . More specifically, the units of the program are operated so that new 3-D shape reconstructed from the 2-D image.
The display unit 26 is, for example, a liquid crystal display, a CRT (cathode ray tube), a video projector, or the like. An image is displayed on the display unit 20 based on the input 23-D image data or the reconstructed 3-D shape data.
The manipulation unit 28 is, for example, a keyboard or a mouse. By the user's manipulation of the manipulation unit 28 , the image processing apparatus 16 integrates a plurality of the 3-D shape data.
<Second Embodiment: Image Processing Method>
Before an explanation of the image processing method, planes that are configured by a pattern projected from projector is defined.
Referring to FIG. 3 , a line pattern that is projected from projector 12 defines a plane in a 3D space. In other words, a straight pattern projected by the projector sweeps a plane in 3D space. Planes defined by a vertical pattern and a horizontal pattern are respectively referred to as a vertical pattern plane (VPP) and a horizontal pattern plane (HPP). The projector is assumed to have been calibrated. That is, all parameters for the VPPs and HPPs in 3D space are known (Hereafter, all the parameters and 3D positions for planes, lines and points are represented in the camera coordinate system.). A VPP and a HPP with known parameters are referred to as a calibrated VPP (CVPP) and a calibrated HPP (CHPP). In addition, all CVPPs are assumed to contain the same line (such a set of planes is also known as a pencil of planes). The same assumption holds for all CHPPs. These lines are denoted as L v and L h and the optical center of the projector O p is the intersection of these lines. The point O p and the direction vectors for L v and L h are given by calibrating projector 12 and camera 14 . Intersections of the vertical and horizontal patterns projected onto the surface of the target scene are extracted from images captured by the camera 14 . Here, these points are referred to as captured intersections. Connectivity between the captured intersections is extracted by image processing. The pattern connecting these intersections can be determined to be a vertical or horizontal pattern, so captured intersections are related in one of two types of relationships, being “on the same VPP” or “on the same HPP”. However, the correspondence from each VPP containing the captured intersections to a particular CVPP is assumed to be unknown. This type of VPPs with unknown correspondences is referred to as unknown VPPs (UVPPs) ( FIG. 4 ). The term unknown HPP (UHPP) is similarly defined. The goal of the problem is deciding correspondences from all the UVPPs and UHPPs to CVPP or CHPP (the decision is called, in other words, identifying UVPPs and UHPPs). Since UVPPs have one-to-one correspondences with detected vertical patterns and the CVPPs are known 3D planes, the 3D positions of points on a detected vertical pattern can be obtained by light sectioning method using correspondences between UVPPs and CVPPs. If a projected line of a single CVPP becomes discontinuous on the image because of occlusions or other reasons, it can be observed as multiple vertical patterns. In this case, multiple UVPPs correspond to a single CVPP. The same things happen for UHPPs and CHPPs.
In the following, a method of image processing is described in detail. Referring to FIG. 2 , an image processing method according to the embodiment includes: a step S 10 to obtain data which is required for reconstruction of 3D shape of object, step S 11 to calculate a solution by using coplanarity constraint existing in UVPP or UHPP, step S 12 to eliminate a degree of freedom of the solution by matching between set of UVPP or UHPP and set of CVPP or CHPP, and step S 13 to reconstruct 3D shape from the calculated solution. In the invention, a degree of freedom of indeterminacy of the solution calculated at step S 11 is one, therefore, all the UVPP and UHPP can be determined by deciding one parameter in step S 12 . Such a process can be done by, for example, one dimensional search to minimize the sum of matching error between two planes.
Hereinafter, these steps are described in detail.
Step S 10
In the step, a data that is necessary for 3D reconstruction of object 18 in FIG. 1 is acquired using image processing unit 10 . More specifically, light of patterns that includes multiple patterns that are crossed at right angles is projected to object 18 . Here, as an example shown in FIG. 7(A) , light of patterns that are composed of vertical patterns and horizontal patterns that are crossed at right angles is projected from projector 12 . Then, the reflected light from the object is captured by camera 14 . Information from 2D images captured by camera 14 is an input to image processing method 16 . By performing the image processing to an input 2D image of image processing method 16 , 2D positions of intersection points between patterns are extracted by means of image processing. In FIG. 7(B) , examples of detected patterns or detected intersection points are shown.
Step S 11
In the step, a method for obtaining constraint equations about UVPPs and UHPPs from intersection points that are captured by the camera, and for obtaining solutions of the planes (first solution) except for one degree of freedom. First, the symbols for referring relevant planes (CVPP, CHPP, UVPP, UHPP) are defined.
Let the CVPPs obtained by calibration be represented as V 1 , V 2 , . . . , V M , CHPPs be represented as H 1 , H 2 , . . . , H N . Also, let the UVPPs and UHPPs obtained from the captured image be represented as v 1 , v 2 , . . . , v m and h 1 , h 2 , . . . , h n , respectively.
Suppose that the intersection between v k and h l is captured and its position on the image in the coordinates of the normalized camera is u k,l =[s k,l , t k,l ] T . The planes v k and h l can be represented by
[Equation 1]
v k T x=− 1 , h l T x=− 1. (1)
respectively, where 3D vectors v k and h k are vectors of plane parameters and x is a point on each plane. Let the 3D position of the intersection u k,l be x k,l , then x k,l can be represented using the coordinates of the image as
[Equation 2]
x k,l =γ[u k,l T 1] T (2)
By substituting x=x k,l into equation (1), and eliminating x k,l and γ from equations (1) and (2),
[Equation 3]
[u k,l T 1]( v k −h l )=0 (3)
is obtained. This equation is a linear equation with variables v k and h l . Accumulated equations for all the captured intersection points become simultaneous linear equations with variables v l , . . . , v m , h l , . . . , h n . Let a matrix representation of these equations be Aq=0, where q=[v l T , . . . , v m T , h l T , . . . h n T ] T .
Since only the substitution (v k −h l ) appears in the equation (3), for a solution q=[v l T , . . . , v m T , h l T , . . . , h n T ] T of Aq=0, a vector that is multiplication of q by a scalar, i.e., s q=[s v l T , . . . , s v m T , s h l T , . . . , s h n T ] T , is also a solution. Similarly, a vector that is addition of q and a constant vector that is concatenation of a constant 3D vector c, i.e., q+[c T , c T , . . . , c T ] T =[v l T +c T , . . . , v m T +c T , h l T +c T , . . . , h n T +c T ] T is also a solution. Using this fact, the general solution of Aq=0, can be written as
[Equation 4]
v k =sv′ k +c, h l =sh′ l +c (4)
where q′=[v′ l T , . . . , v′ m T , h′ l T , . . . , v′ n T ] T is a special solution of Aq=0.
In this invention, there are assumed conditions that all the UVPPs include line L v and all the UHPPs include line L h . Also, L v and L h intersects at point O p . From these conditions, there are constraints between arbitrary variables s and c of equation (4), and the freedoms of the solution is reduced. In the following, how to obtain general solution considering these conditions is described. The plane that includes both L v and L h is referred to as the projector focal plane (PFP) and its plane parameter is described as p. Let the direction vectors of the line L v and L h be represented as l v and l h respectively. Also, let the 3D coordinate vector of the optical center O p of the projector be o p . UVPPs contain the line L v , UHPPs contain the line L h , and all the planes contain the point O p . Thus,
[Equation 5]
l v T v k =0 , l h T h l =0 , o p T v k =−1 , o p T h l =−1 (5)
are obtained. In addition, we assume that the special solution q′ defined above fulfills the same conditions. This means that
[Equation 6]
l v T v′ k =0 , l h T h′ l =0 , o p T v′ k =−1 , o p T h′ l =−1 ( 6 )
holds. In addition, since PFP include line L v , L h and point O p ,
[Equation 7]
l v T p= 0 , l h T p= 0 , o p T p=− 1 , o p T p=− 1 (7)
holds. From equations (5), (6) and (7)
[Equation 8]
l v T ( v k −p )=0 , l h T ( h l −p )=0 , o p T ( v k −p )=0 , o p T ( h l −p )=0 , l v T ( v′ k −p )=0 , l h T ( h′ l −p )=0 , o p T ( v′ k −p )=0 , o p T ( h′ l −p )=0 (8)
are obtained. From these equations, both v k -p and v′ k -p are perpendicular to both l v and o p . Since l v and o p are not parallel in general, the vector that is perpendicular to these two vectors can be determined uniquely except for the scaling. Thus,
[Equation 9]
( v k −p )= s ( v′ k −p ) (9)
is obtained. Similarly,
[Equation 10]
( h k −p )= s ( h′ k −p ) (10)
holds. From equation (9), (10), the general solution of equations (3) and (5) is
[Equation 11]
v k =s ( v′ k −p )+ p, h l =s ( h′ l −p )+ p (11)
As already described, [v′ l T , . . . , v′ m T , h′ l T , . . . , v′ n T ] T is a special solution, and p is a parameter vector of plane PFP. Because indeterminacy of the general solution (4) is reduced by conditions L v and L h , the remaining indeterminacy of equation (11) is only one degree of freedom of scalar s.
Equation (11) means that, from images of intersection points between vertical patterns and horizontal patterns, the positions of their corresponding planes (i.e. UVPPs and UHPPs) can be solved except for one degree of freedom. Obtaining this representation of solution needs requirements such as follows. We define that, if an intersection point between two curves of a UVPP and a UHPP is detected, the two planes are connected. We also define that, if planes a and b are connected and planes b and c are connected in the above meaning, then planes a and c are connected. For a set of UVPPs and UHPPs, and an arbitrary element of the set is connected to all the other elements, then the set is called a connected set. FIG. 5 shows an example of a connected set. Under these definitions, if a set of UVPPs and UHPPs are a connected set, then the solutions of the positions of all the planes in the set can be solved by equation (11).
Intuitively, this can be proved as the following: With respect to a single UVPP v f , the positional indeterminacy is one degree of freedom, since v f include a line L v . Here, we set the unsettled single parameter of v f to an assumed value, and then, consider a UHPP h g that has an intersection point with v f . By deciding the position of v f , the position of h g is also fixed because the 3D position of the intersection point can be calculated and h g includes line L h . Similarly, if a plane is fixed, then, other planes that share intersection points to the fixed plane can also be decided. By repeating this process, we can fix all the planes for an entire connected set. In this case, the indeterminacy is only one degree of freedom for the first plane. The equation (11) expresses this form of solution. However, if a set of UVPPs and UHPPs is not a connected set, the degree of freedoms of the whole solution is equal to or more than 2, since there are no constraints between planes that are not included in a single connected set. Thus, a necessary and sufficient condition for the set of all the planes to be expressed by equation (11) is that the set is a connected set.
In this invention, the set of UVPPs and UHPPs are assumed to be a connected set, if multiple connected sets are obtained from the target scene, it is sufficient to apply the invention for each of the connected sets. Thus, this does not reduce generality of the invention. Dividing UVPPs and UHPPs into connected sets can be easily implemented using labeling process applied to the images. Another efficient method to achieve the same result is examining the connection relationships of a graph that are composed of detected vertical and horizontal patterns and captured intersection points.
Depending on the supposed applications, the solution with remaining one degree of freedom obtained in step 11 can be sufficiently useful. For example, in the case that the focal length of the projector light source is long (thus, it is nearly a parallel light source), the remaining parameter of the solution with one degree of freedom may be decided arbitrary because the distortion of the shape becomes relatively small. Thus, in this case, for limited use in which the shape is rendered with shading, the output of step S 10 may be a sufficiently useful result. In particular, if it is rendered to only a 2D display, the rendered image seems natural enough, and can be used for movies, games, or digital archives as it is. Thus, output of step S 11 can be a practical result.
Step S 12
In this step, matching is processed between the solution obtained in the previous step and the set of CVPPs and CHPPs, and the result is correspondences between UVPPs and CVPPs, or correspondences between UHPPs and CHPPs. This means that a parameter of the solution of the previous step is decided such that the solution and the set of CVPPs and CHPPs coincide. The solution of the previous step of UVPPs and UHPPs is obtained from only the captured intersection points, and information of CVPPs and CHPPs is not used. Since the degree of freedom of the solution is one, matching can be processed efficiently using 1D search, and a solution with no remaining degrees of freedom (second solution) can be obtained.
First, we define expressions for correspondence between UVPPs and CVPPs. If the k-th UVPP v k corresponds to the i-th CVPP V i , it can be written as v k →V i . This means that v k is identified as V i .
Explanation of specific pattern matching processing is as follows. First, an arbitrary UVPP is selected. For example, we suppose that v 10 is selected. Then, v 10 corresponds to CVPPV l , and the positions of all the UVPPs and UHPPs (i.e. v l , . . . , v m , h l , . . . , h n ) based on the correspondence. In this process, it is evaluated that if the set of obtained positions of UVPPs and UHPPs (v l , . . . v m , h l , . . . , h n ) matches to set of CVPPs and CHPPs (V 1 , . . . , V M , H l , . . . , H N ).
Then, the corresponding plane v 10 is changed to V 2 , V 3 . . . and each set of plane positions of UVPPs and UHPPs obtained form the correspondences is evaluated if it matches the set of UVPPs and CHPPs.
Based on the positions of UVPPs and HUPPs that is evaluated as the best matching to the set of CVPPs and CHPPs, its correspondences between UVPPs and CVPPs, and its correspondences between UHPPs and CHPPs are output as the solution.
Evaluation method for matching is described below. Form (11) has an indeterminacy of parameter s. The parameter can be calculated as follows by assuming a specific correspondence between a UVPP and CVPP. By assuming the correspondence from the k′-th UVPP to the i′-th CVPP (i.e. v k′ →V i′ )
[Equation 12]
V i′ =v k′ =s ( v′ k′ −p ) (12)
holds, where V i′ is the parameter vector of the CVPP V i′ . From this form, s can be calculated by
[Equation 13]
s=∥V i′ −p∥/∥v′ k′ −p∥ (13)
From the calculated s, all the UVPPs and UHPPs under an assumption of vk′→Vi can be calculated.
Let this s of the form (13) be denoted as s(k′, i′). Then, v k and h l given the correspondence v k′ →V i′ , which we refer to as v k (k′, i′) and h l (k′, i′), respectively, can be calculated by
[Equation 14]
v k ( k′, i ′)= s ( k′, i′ )( v k −p )+ p, h l ( k′, i′ )= s ( k′, i′ )( h l −p )+ p (14)
The next step is comparing the calculated UVPPs (or UHPPs) with the CVPPs (or CHPPs). For each UVPP, the difference between the UVPP and the nearest CHPP is calculated as an error. Then, we can define a match estimation for an assumed correspondence v k′ →V i′ as the sum of squared errors for all the UVPPs (the smaller the squared errors are, the better matched the plane sets are). By searching for the minimum of the error function, we can find the optimum correspondence and solve the ambiguity.
The comparisons are executed between UVPPs v k (k′, i′),(k=1, . . . , m) and CVPPs V i , (i=1, . . . , M), and also between UHPPs h l (k′, i′),(l=1, . . . , n) and CHPPs H j , (j=1, . . . , N). In this paper, comparison is done based on the squared angles between the planes. More specifically, the error function is defined as
[ Equation 15 ] E k ′ ( i ′ ) ≡ ∑ k = 1 m min i = i , … , M { D ( v k ( k ′ , i ′ ) , V i ) } 2 + ∑ l = 1 n min j = 1 , … , N { D ( h l ( k ′ , i ′ ) , H j ) } 2 . ( 15 )
where D means the angle between two planes which can be defined as
[Equation 16]
D ( v k , V i )≡arccos(( v k ·V i )/(∥ v k ∥ ∥V i ∥)) (16)
Using these forms,
[ Equation 17 ] i min ′ ≡ arg min i ′ E k ′ ( i ′ ) ( 17 )
is finally searched, and the set of planes v k (k′, i′ min ), (k=1, 2, . . . , m) and h l (k′, i′ min ), (l=1, 2, . . . , n) is the solution.
There are another method for comparing the set of calculated UVPPs and UHPPs and the set of CVPPs and CHPPs. For example, one can compare the set of intersection lines between UVPPs and UHPPs (there are multiple intersection lines because there are multiple UVPPs and UHPPs) with the set of intersection lines between CVPPs and CHPPs. Let us call the former set by IUPP (Intersections between Uncalibrated Projector Planes), and let us call the latter set by ICPP (Intersections between Calibrated Projector Planes). As a criteria to measure the match, for each h in IUPP, elements in ICPP is searched, and g in ICPP such that d(g,h) becomes the minimum, where d(g,h) means a difference of angle between direction vectors of line g and line h. The same process is applied for all the h, and the error function is defined as the sum of squares of the angle differences d(g,h). The parameter such that the error function is the minimum can be obtained, as similarly to step S 12 .
Other methods can be applied if the method is about comparing the detected patterns and the known patterns. For example, a case that a vertical pattern detected as a boundary of a vertical band-like pattern can be considered. In this case, the vertical pattern of a certain UVPP and the corresponding CVPP should be the same about whether the pattern is the left side boundary or the right side. In other words, UVPP of the right-side boundary should be corresponded to CVPP of the right-side boundary. This can be reflected to error function that estimates the matching, or can be used for the search process of the matching parameter. In addition, if there is a method for classifying some intersection points form others, it can be used to estimate the matching. For example, some intersection points can be marked by markers such as circles in the used pattern, then, the matching of the circled intersection points can be used for estimate matching between the set of UVPPs and UHPPs and the set of CVPPs and CHPPs.
Step S 13
In the step, since all the UVPPs are identified in the previous processes, the shape is reconstructed by light sectioning method. More specifically, as shown in FIG. 6 , the 3D points on object 18 are calculated as intersection points between the plane parameter and the line of sight that includes both detected edges and the optical center of camera 14 .
By processing the previous steps, the 3D shape of the object captured by the camera can be reconstructed.
<Third Embodiment of the Present Invention: Positional Relationship between the Camera and the Projector>
One can improve the precision of the measurement by precisely calibrating the positional relationship between the camera and the projector before the measurement. One method to do that is calibrating parameters using calibration objects. On the other hand, processing calibration before measurement can be a burden. Thus, at the measurement process, processing a self-calibration by projecting a certain set of patterns onto static objects can be useful. This method is described in, for example, Ryo Furukawa, Hiroshi Kawasaki, “Dense 3D Reconstruction with an Uncalibrated Stereo System using Coded Structured Light,” IEEE Computer Society Conference on Computer Vision and Pattern Recognition (CVPR'05) Workshop on Projector-Camera Systems, p. 107, 2005.
<Fourth Embodiment: The Positional Configuration of the Projected Patterns>
Next, patterns projected from projector 12 are described.
The positional configuration of the projected patterns (CVPPs and CHPPs) affects stability of the search expressed as equation (17). Let us suppose that the true correspondences between planes to be v l T →V l , . . . , v m T →V m , h l →H l , . . . , h n →H n . If there are no errors in the solution, V l =v l , . . . , V m =v m , H l =h n . . . , H n =h n for the true s of equation (11). However, let us assume that there exist a value s′ that is different from the true s of equation (11), that the value s′ produces UVPPs and UHPPs(v l , . . . , v m , h l , . . . , h n ) at different positions from their true positions, and that there exists q and r such that V q =v k , (k≠q), H r =h i , (i≠r) for arbitrary k and i. Then, the value s′ cannot be discriminated from the true value s. Thus the unique solution cannot be obtained.
Generally, this kind of situation does not occur. However, in cases that CVPPs and CHPPs are arranged regularly, then, the evaluation function does not change much even if all the correspondences are changed by one position and the solution tend to become unstable. One method to prevent this is arranging CVPP and CHPP at irregular intervals on the image plane of the projector. This method makes the plane positions of the sets Vq and Hr irregular, and prevents the abovementioned condition. In actual cases, it is not required that both of the sets are irregular, and the instability can suppressed by arranging CHPPs at irregular intervals, and arranging CVPPs regularly (with uniform intervals) and denser than CHPPs. The advantage of this configuration is that the search stability is achieved by irregularity of CHPPs, and that the density of resulting points can be increased by dense CVPPs. An example of such patterns is shown in FIG. 7 . Even if the arrangement of CHPP is based on some rules rather than irregular intervals, the stability can be increased by using non-uniform spacing. This is another solution.
In the invention, not like a common one-shot scanning technique which identifies each local pattern, a pattern is not required to be encoded like deBruijn sequence, and a single color is sufficient. Since a single color is sufficient, the technique is less affected by texture color and a stable detection is possible by simple image processing. Further, it is not spatially encoded, one pixel width of pattern is sufficient and very dense shape reconstruction can be achieved.
In addition, in this invention, it is sufficient to classify each of the single-colored patterns into classes of vertical patterns or horizontal patterns. Thus, it is robust against textures. However, there remain problems about shapes of the target. For example, in case that the target shape is a cylinder, where normal directions at the front region and the side region are different largely, with a pattern of uniform frequency may result in detection failure, because the appearances of the pattern are compressed at the side regions. In this invention, adding patterns with different special frequency can solve this problem. To achieve the solution by using projectors and cameras that are available on the market, we use only three colors of RGB. One color is used for the horizontal patterns that are single-colored, irregular and coarse, and the other two colors are used for regular patterns with coarse and dense intervals. An actual example of such pattern is shown in FIG. 8(A) . The detection result of vertical and horizontal patterns using this pattern is shown in FIG. 8(B) and FIG. 8(C) . One can see that coarse grids and dense grids are detected respectively. In the following explanation, this type of pattern configuration and processing is called coarse-to-fine.
For multiple patterns used for coarse-to-fine, different patterns can be parallel patterns with different density, or they can be completely independent patterns.
To further improve coarse-to-fine method, one can increase the number of patterns with different densities. Even in this case, since the invention is used for only increasing spatial frequencies, classifying 10 patterns are enough for a camera with 1024 (=10 bits) pixel resolution in the worst case (the case where the highest number of patterns are needed). Thus, it is fundamentally different from the previous methods that encode information into patterns spatially. Classifying 10 patterns can be easily achieved by using methods such as narrow band-pass filters.
For reconstruction, results of FIG. 8(B) and FIG. 8(C) can be reconstructed independently and the resulting shapes can be merged. For methods for merging, a simple way that is easy to implement is taking union of the results. More precise method is improving coherency of lines shared by dense and coarse patterns based on statistical methods.
As another method, instead of reconstructing two patterns independently, one can reconstruct shapes using all the patterns of horizontal pattern, coarse vertical pattern, and dense vertical pattern. If the coarse vertical pattern and the dense vertical pattern are parallel as shown in FIG. 8(A) , all the patterns of coarse vertical pattern and the dense vertical pattern can be regarded as a set of vertical patterns.
To increase the precision of the solution, in addition to the basic grid-like pattern, one can add other line-based patterns. The additional line patterns can be processed similarly as the abovementioned method: they can be represented as plane parameters written in the form of equation 1, linear equations are constructed for each of the intersection points with all the patterns, and, since a plane corresponding to each of the patterns includes a line that is decided from the direction of the pattern, simultaneous linear equations can be generated using methods that are similar to equations 9, 10. By solving the equations, one can reconstruct shapes for patterns with a set of lines whose directions are more than three kinds of directions. Using this method, one can solve the case of non-parallel sets of dense and coarse vertical lines (not like the example of FIG. 8(A) ) by simply solving one set of equations).
<Fifth Embodiment of the Present Invention: Using Means for Projecting Parallel Planes>
In the second embodiment, we assume that the set of planes of the vertical patterns (or horizontal patterns) is a set of planes that share a single line. Instead of this assumption, we can also use parallel planes. In this case, the condition that the planes share a single line is replaced by the condition that “the planes share a single line at infinity”. Then, the lines L v and L h in the second embodiment share a single point at infinity O p . By this consideration, equation O p T v k =−1 in equation (5) can be replaced by O p T v k =0. Similarly, by replacing the right side value −1 of equations (5), (6), and (7) by 0, we can obtain constraints that parallel planes comply. By using these constraints, solutions with one degree of freedom can be obtained, similarly as the second embodiment.
A real system can be achieved by arranging line-laser light sources in parallel. Using this configuration, one can get the pattern light with the same intervals even if the object moves far away from the light source. Thus, the light source can be placed far away from the target, and can be useful for 3D measurement.
<Sixth Embodiment: Detection Algorithm of Patterns>
If the vertical and horizontal patterns are colored in red and blue, respectively, these lines are divided by using red and blue planes of the captured image. For line detection method, using simple thresholding is one method. However, since the intensity of the line can be varied by distance from the light source to the surface, or by difference of normal directions of the surface points, it is difficult to achieve precise line detection for all the image by simple thresholding. In this case, using edge filters such as canny filters is a method to achieve stable result. However, edge filters may be affected by erroneously detected edges of textures or of boundaries of objects. One method to avoid this is dividing the whole image into small blocks, a threshold value is decided for each of the blocks, and detecting lines for each block by thresolding.
One can also arrange the projector and the camera, by keeping the directions of the devices at parallel positions and by rotating each of the camera and the projector by 45 degrees. In this case, vertical and horizontal projected patterns that are crossed by right angles can be detected, even in the camera coordinates, as vertical and horizontal patterns that are crossed by right angles. Thus, in scanning the captured image in vertical or horizontal directions, a same pattern is not scanned twice. Using this configuration, and by using algorithm of detecting peaks on the scanlines, problems of simple shareholding, problems of textures, and problems of edges of occluding boundaries can be resolved.
<Seventh Embodiment: Reducing the Number of Equations>
In the abovementioned second embodiment, the number of variables in the equations is 3(m+n) where m is the number of UVPPs and n is the number of UHPPs. By reducing the number of variables, the time for processing the data can be much reduced. By reducing the variables using the following method, the time for calculating the solution that include degrees of freedom can be reduced by 1/100000, resulting in an efficient 3D reconstruction.
In the following, by using property of planes that all the planes share a single line, planes are represented by a single parameter. Thus, the number of variables is reduced by ⅓, and the processing time for reconstructing 3D shapes is reduced.
Specifically, we assume that both v k and h l are planes that includes o p (this plane is PFP and expressed as p), and the two planes are perpendicular to l v and l h respectively. By defining
[Equation 18]
v ≡l v ×o p , h ≡l h ×o p (18),
we can express
[Equation 19]
v k =η k v +p, h l =ρ l h +p (19)
In expression (19), v k and h l are expressed by single parameters (η k , ρ l ). Thus from equation (3),
[Equation 20]
ũ k,l T {(η k v +p )−(ρ l h +p )}=0 ⇄( ũ k,l T v )η k −( ũ k,l T h )ρ l =0 (20)
where ũ k,l is defined as ũ k,l ≡[u k,l T 1] T
If the i-th intersection point is one between v k and h l , then, we define α(i)≡k, β(i)≡l. Then, the equation from the i-th intersection points can be written as the following:
[Equation 21]
( ũ i T v )η α(i) −( ũ i T h )ρ β(i) =0 (21)
where ũ α(i),β(i) ≡ũ i
By defining m to be the number of UVPPs, n to be the number of UVPPs, K to be the number of intersection points, this condition can be written as the following: using definitions
[Equation 22]
φ( i )≡( ũ i T v ), ψ( i )≡( ũ i T h ) (22)
[ Equation 23 ] P ≡ 1 ⋮ i ⋮ K ( … … … … … … … … … … … ϕ ( i ) … - ψ ( i ) … … … … … … … … … … … ) 1 … α ( i ) … β ( i ) … m + n , ( 23 )
[Equation 24]
q≡[η 1 , . . . , η m , ρ 1 , . . . , ρ n ] T (24)
then, the conditions can be expressed as a homogeneous linear equation written as
[Equation 25]
Pq=0 (25)
This equation expresses conditions of equation (3) with additional conditions of equation (19) that means UVPPs include L v and UHPPs include L h . Thus, the abovementioned general solution can be obtained by solving this equation. Because the variable vector q of this equation is (m+n)-dimensional vector, this method reduces 3(m+n) variables to (m+n) variables.
Next, a method for reducing the number of variables to the number of horizontal planes is explained. The reduction is achieved by converting the abovementioned equations to equations with variables of parameters of only the horizontal planes (UHPPs).
First, we solve equation (25) by minimizing the norm of the left side of the equation considering noise. By defining the squared norm of the left side to be Ep≡∥Pq∥ 2 , then the following equation holds:
[
Equation
26
]
E
p
=
∑
N
p
{
ϕ
(
i
)
η
α
(
i
)
-
ψ
(
i
)
ρ
β
(
i
)
}
2
(
26
)
This equation is partially differentiated with respect to η j . By defining α−1(j)≡{k|α(k)=j}, the following equation holds:
[
Equation
27
]
∂
E
p
∂
η
j
=
∑
k
∈
α
-
1
(
j
)
∂
∂
η
j
{
ϕ
(
k
)
η
j
-
ψ
(
k
)
ρ
β
(
k
)
}
2
=
∑
k
∈
α
-
1
(
j
)
2
ϕ
(
k
)
{
ϕ
(
k
)
η
j
-
ψ
(
k
)
ρ
β
(
k
)
}
=
2
η
j
∑
k
∈
α
-
1
(
j
)
{
ϕ
(
k
)
}
2
-
2
∑
k
∈
α
-
1
(
j
)
ϕ
(
k
)
ψ
(
k
)
ρ
β
(
k
)
(
27
)
To minimize Ep, we solve ∂Ep/∂ρ j =0. Since
[
Equation
28
]
η
j
∑
k
∈
α
-
1
(
j
)
{
ϕ
(
k
)
}
2
=
∑
k
∈
α
-
1
(
j
)
ϕ
(
k
)
ψ
(
k
)
ρ
β
(
k
)
,
we
obtain
the
following
equation
:
(
28
)
[
Equation
29
]
η
j
=
∑
k
∈
α
-
1
(
j
)
ϕ
(
k
)
ψ
(
k
)
ρ
β
(
k
)
∑
k
∈
α
-
1
(
j
)
{
ϕ
(
k
)
}
2
(
29
)
Thus, ρ j can be expressed as a linear combination of η k . This can be expressed as
[Equation 30]
η = T ρ (30)
where we use the following definitions:
[
Equation
31
]
ω
(
j
)
≡
1
/
∑
k
∈
α
-
1
(
j
)
{
ϕ
(
k
)
}
2
,
(
31
)
[
Equation
32
]
χ
(
k
)
≡
ϕ
(
k
)
ψ
(
k
)
,
(
32
)
[
Equation
33
]
T
≡
⋮
j
⋮
(
…
…
…
…
…
…
w
(
j
)
χ
(
k
1
)
…
ω
(
j
)
χ
(
k
2
)
…
…
…
…
…
…
)
…
k
1
…
k
2
…
,
(
33
)
[
Equation
34
]
η
_
≡
[
η
1
,
…
,
η
m
]
⊤
,
(
34
)
[
Equation
35
]
ρ
_
≡
[
ρ
1
,
…
,
ρ
n
]
⊤
(
35
)
In definition of T, the column indexes k 1 , k 2 , . . . are elements of α −1 (j), which is the set of indexes of all the UHPPs that have intersection points with the j-th UVPP. Then, from
[ Equation 36 ] q = [ η _ ρ _ ] = [ T I ] ρ _
and by defining ( 36 ) [ Equation 37 ] R ≡ [ T I ] ( 37 )
then, minimizing ∥Pq∥ 2 is equivalent to minimizing
[Equation 38]
∥ Pq∥ 2 =∥PRq∥ 2 =q T ( R T P T PR ) q (38)
The minimization of this equation is equivalent to solving the equation
[Equation 39]
PRq=0 (39)
by considering errors by minimizing the sum of squared errors. This can be solved by calculating the eigenvector of matrix R T P T PR T that is associated to the minimum Eigen value. R T P T PR T is a n×n matrix. If we use dense vertical patterns and coarse horizontal patterns, n (the number of UHPPs) is much smaller than m (the number of UVPPs). In this case, the above problem can be solved much efficiently than solving the problem of minimizing ∥Pq∥ 2 with respect to q.
First, to demonstrate the effectiveness of the invention, the proposed method is tested using data synthesized by a simulation. The simulation is done using multiple grid patterns. The first pattern is uniformly spaced grid pattern. The second pattern is purpose-fully randomized to disturb the uniformity of the grid pattern. Using the second pattern, one can expect increased stability of searching for correspondences as already described reasons. The simulated images for each of the experimental grid patterns are shown in FIG. 9(A) and FIG. 9(B) . In the images, the intervals of the vertical patterns were about 5 pixels. The intersections of the grid patterns were extracted from the images and the correspondences from the UHPPs and UVPPs to the CVPPs and CHPPs were determined using the proposed method. In the results of both patterns, the correct correspondences for all the UHPP and UVPP were selected and the reconstructed shapes exactly matched the ground truth. The shape obtained using the second pattern with the ground truth is shown in FIG. 9(C) .
Next, several experiment were conducted to evaluate the stability of the proposed method when the input data (the set of captured intersections) were disturbed by noise. Since the stability of the proposed method depends on the projected pattern, the two types of patterns shown in FIGS. 10(A) and (B) were used and isotropic 2D Gaussian noise was added to the captured intersections. The proposed method was applied to data with various noise levels, where noise levels were standard deviations of the noise in pixels. 20 tests were conducted for each noise levels. The error ratios of the searches of i min are shown in FIG. 10(C) . The results confirmed that stability of the algorithm was improved using the pattern with random intervals.
An actual 3D scanning system was built as shown in FIG. 11 . Patterns were projected by a projector with a resolution of 1024×768 and scenes were captured by a CCD camera (720×480 pixels). Then 3D reconstruction is conducted.
FIG. 12 shows the captured scenes and results of reconstruction. In the experiment, a ceramic bottle, a paper mask and a ceramic jug with an intricate shape were captured. As is apparent, detailed shapes were successfully recovered with the current method. Specifically, FIG. 12(A) shows a target object, FIG. 12(B)-FIG . 12 (E) show the reconstruction result. FIG. 12(F) shows a target object and FIG. 12(G)-FIG . 12 (I) show the reconstruction result.
Next, by referring FIG. 13 , a scene of a box (size: 0.4 m×0.3 m×0.3 m) and a cylinder (height: 0.2 m, diameter: 0.2 m) was measured by the abovementioned coarse-to-fine method. For evaluation, the same scene was measured by a coded structured light method as a ground truth. Here, FIG. 13(A) shows the captured object, FIG. 13(B) and FIG. 13(C) show input image, FIG. 13(D) shows detected horizontal patterns, FIG. 13(E) shows detected dense vertical patterns, FIG. 13(F) shows detected coarse vertical patterns, FIG. 13(G) shows the intersection points of dense patterns, FIG. 13(H) shows intersection points of coarse patterns, FIG. 13(I) shows reconstructed shape of dense patterns, FIG. 13(J) shows reconstructed shape of coarse patterns, FIG. 13(K) shows the unified result, and FIG. 13(L)-FIG . 13 (N) show the reconstructed shape and the ground truth shape.
By using combination of coarse and dense vertical patterns, the shape with different normal directions could be measured densely without missing regions. And, although there were small differences between the reconstruction and the ground truth, the RMS error of the reconstruction from the ground truth was 0.52 mm. Thus, the shape was correctly restored.
Finally, by referring FIG. 14 , a human face was measured. The appearance of the experiment is shown in FIG. 14(A) and FIG. 14(B) . Three examples of the reconstructed face expression is shown in FIGS. 14 (C)-(E). Results indicate that the proposed method successfully restored the complex human facial expressions with dense and accurate 3D point clouds. | Provided are an image processing device, an image processing method, and a program which are capable of high density restoration and which are also strong to image processing. An image processing device mainly consists of a projector serving as a projection means, a camera as a photographing means, and an image processing means consisting of, for example, a personal computer. The image processing means acquires the intersection point between patterns from a photographed image and calculates a first solution including degree of freedom by using the constraint condition of a first tentative plane and a second tentative plane including the intersection point and the constraint condition obtained from the positional relationship between the projector and the camera. The degree of freedom is cancelled by primary search, thereby restoring a three-dimensional shape. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of PCT/US03/25910, filed on Aug. 19, 2003, which claims priority from U.S. provisional application, Ser. No. 60/404,487, filed Aug. 19, 2002. The entire disclosure of both applications is incorporated herein by reference.
FIELD OF THE INVENTION
The invention relates to wholly aromatic liquid crystalline polymers.
BACKGROUND OF THE INVENTION
Liquid crystalline phases (mesophases) are partially ordered intermediate phases existing between the crystalline solid and isotropic liquid Materials in a liquid crystalline phase can flow like liquids, while retaining several features of crystalline solids such as optical and electromagnetic anisotropy characteristics. These properties are due to a specific amount of positional or orientational order in their structure. Mesogens or mesogenic groups are chemical moieties that induce mesophases under certain conditions. According to the ways to generate a liquid crystalline phase, these groups can be classified as lyotropic (exihibits liquid crystalline phase in solution) and thermotropic (exhibits liquid crystalline phase in melt, a single component system) liquid crystals.
The two main types of liquid crystalline phases are the nematic and smectic mesophases. In nematic phases the molecules have only an orientational order, while in smectic phases they have both orientational and positional order in one or more dimensions.
When a thermotropic LC compound is heated, the solid changes into a rather turbid liquid at the melting point. The fluidity may be high for a nematic phase and relatively low for the smectic phases. When observed between crossed polarizers under a microscope, the fluid is found to be strongly birefringent. Upon further heating, another transition point is reached where the turbid liquid becomes isotropic and consequently optically clear (clearing point). Between these two transition points, the liquid crystal phase is thermodynamically stable Both phase transitions are first order and the latent heat at the clearing point is usually an order of magnitude smaller than the melting point.
The polarizing m is a classical and useful tool for the study of liquid crystals. Dependent upon the boundary conditions and the type of LC phase, specific textures are observed and used to classify the different phases.
Liquid crystal polymers were discovered in the 1950s, when Onsager and Flory theoretically predicted that rigid rod-like macromolecules should display liquid crystalline properties. An axial ratio of 6.42 is enough for a polymer to form an LC melt. However, the molecular weight must be high to achieve good mechanical properties. The first main chain thermotropic liquid crystalline polymer was reported by Roviello and Sirigu in the 1970s, and since then many patents have been published and several LC polymers were commercialized.
Compared to monomer liquid crystals, polymer liquid crystals can display similar behaviors, and be classified into thermotropic and lyotropic LCPs. Several well known classes of polymers including polyesters, polyethers and polyamides can exhibit liquid crystalline phases. According to different mesogen positions in the polymer, LC polymers can be classified as main chain, side chain and combined liquid crystal polymers. More complex architectures are also possible.
LCPs are quite different from the conventional polymers. They have properties that include low melt viscosity, fast cycle time in molding, very low mold shrinkage, excellent mechanical properties, solvent resistance, excellent barrier properties, low water absorption, low thermal expansion coefficient, excellent thermostability, low flammability, etc. Therefore, they have been explored for numerous applications in the following areas: high-strength and high-modulus fibers, precision molded small components, films exhibiting excellent barrier properties, novel composites, processing aids in the melt, reversible information storage, electro-optical displays and non-linear optical devices.
The mesogenic groups in LCPs are usually rod-like or disk-like molecules, such as two or more rigid cyclic units. Aromatic rings are the most common units used in liquid crystal polymer to provide rigid rod structures. The synthesis, structure, rheology, processing, performance and applications of many LCPs have been comprehensively described in the literature, including Demus, D., et al, Physical Properties of Liquid Crystals ; Wiley-VCH Verlag GmbH: Weinheim, 1999; Kwolek, S. L. Encycl. Polym. Sci. Eng. 1987, 9, 1–61; Collyer, A. A.; Editor. Liquid Crystal Polymers. From Structures to Applications ; Elsevier: London, 1992; Ciferri, A.; Krigbaum, W. R.; Meyer, R. B.; Editor. Polymer Liquid Crystals ; Academic Press: New York, N.Y., 1982; and Isayev, A. I.; Kyu, T.; Cheng, S. Z. D.; Editors. Liquid - Crystalline Polymer Systems: Technological Advances . ( Symposium at the 209 th National Meeting of the American Chemical Society, Anaheim, Calif., Apr. 2–7, 1995.) [In: ACS Symp. Ser., 1996; 632]; ACS: Washington, D.C., 1996.
Thermotropic main chain liquid crystal polymers are the most important group of LCPs. They consist of mesogenic groups incorporated into the backbone of the polymer chain, and when prepared without flexible spacers, are usually known as wholly aromatic thermotropic LCPs. Because of their main chain stiffness and high packing density, they can exhibit excellent mechanical properties and are extremely useful in high-strength and high-modulus fibers. Since they form LC phases when melted, the viscosity in the melt state is relatively low, thus make the processing easy. Furthermore, the rod-like mesogenic groups can be aligned during the extruding or spinning process and give very high strength along the fiber direction.
Polyesters are a very important group of this class of polymers. Structures of some commercially important theremotropic copolyesters are listed in Table 1.
TABLE 1
Structures of some thermotropic co-polyesters
Chemical Structure
Monomers
1
p-hydroxybenzoicacid (HBA)
2
4,4′-biphenol (BP)/Terephthalic acid(TA)
3
6-hydroxy-2-naphthoic acid(HNA)/HBA
4
2-methylhydroquinone (2-MHQ)/TA
5
Isophthalic acid (IA)/HBA/BP/TA
Generally, wholly aromatic thermotropic polyesters have poor solubility in normal organic solvents. Good solvents for this class of polymers include fluorinated compounds, such as pentafluorophenol (PFP), p-fluorophenol, trifluoroacetic acid, etc. Due to the poor solubility in common solvents, GPC data are usually not available in the literature. However, Kinugawa, et al. have investigated the molecular weight distributions of LC aromatic polyesters by the GPC-low-angle laser light scattering technique.
General characterization methods for this class of polymers include differential scanning calorimetry (DSC), polarized light microscopy, and wide-angle X-ray diffraction.
The ability to show anisotropy and readily induce orientation in the liquid crystalline state leads to materials with great strength in the direction of orientation, and thus, these polymers have received considerable attention as high-performance fibers, films and plastics, especially for injection molding applications.
The concept of a melt processable LC polymer is a natural extension of the discovery of KEVLAR® at DuPont, which is a wholly aromatic LC polyamide spun from concentrated sulfuric acid. Ekkcel I-2000 (copolyester from p-hydroxybenzoic acid (HBA), terephtalic acid (TA) and 4,4′-bisphenol (BP)) was the first melt spinable LC polyester reported in 1972. It has a melting point around 400° C., which is still too high for common melt spinning equipment.
In the 1970's and 1980's, aromatic LC polyesters were developed quickly and many LC polyesters were commercialized during this period. XYDAR® was first commercialized by Dartco Manufacturing Company in 1984 and was later manufactured by Amoco Chemical Company. It exhibits a melting point above 300° C. The VECTRA® family of LCPs was introduced by Celanese in 1985, with a melting point of 250–280° C.
Since these types of polymers offer a unique combination of properties, they are expected to offer potential solutions to problems which conventional materials are unable to solve. Currently, industrial activities are mainly concentrated on main chain thermotropic LCPs for injection molding applications.
Homopolymers from HBA or 6-hydroxy-2-naphthoic acid (HNA) exhibit high crystallinity and high melting point (higher than 600° C.). Although they provide excellent mechanical and thermal properties, their high melting points make them intractable and impractical for any commercial applications, since they are not melt spinnable or injection moldable. Thus, research has focused on developing new polyesters that have better tractability (lower melting point) without sacrificing other desirable properties.
The most common way to achieve this is to disrupt the regular chain structure. Until now, several methods were found to be effective in lowering the melting point of LC polyesters, such as the introduction of aliphatic spacer units on the backbone, using monomers with bent structures (kinks), ring substitution, “swivel” structures, and parallel-offset structures (crankshaft) into the backbone. However, a need for additional LCP having a desired balance of properties, including T g , melting point (T m ), tensile strength and/or thermal stability, still exists.
Introducing aliphatic structures can give the backbone more flexibility, which disturbs the packing of the polymer chain and lowers the melting point. Numerous efforts have been made in the LC polyester area using this strategy. One example is X7G. By introducing the PET structure into the polymer, the melting point was lowered to about 230–300° C. Another example is SIVERAS, an LC polyester based on PET, introduced by Toray Industries, Inc. in 1994. It is melt spinable at 310–320° C.
The major drawback for this strategy is that the aliphatic structure also decreases the degree of liquid crystallinity and lowers the thermal stability and mechanical properties dramatically. The properties are decreased in proportion with the length of the flexible spacer and its content in the polymer.
Instead of using para-substituted monomers, meta- or ortho-substitution on the phenyl ring will introduce a bent structure into the backbone, thus disturbing the packing and lowering the melting point. An example of this is Ekonol, which is composed of units derived from monomers HBA, TA, BP and a small amount of isophthalic acid (IA). The polymer exhibits very high tensile modulus and strength as a fiber. The problem with this strategy is that the kink structure can not exceed a specific amount in the total composition, without loss of LC properties. It was reported that for kink units having a 120′ core angle such as isophthalic acid, the polymers will not exhibit liquid crystallinity with more than 60 mol % of kink units of the acids. For kink units having a 60′ core angle, the maximum ratio is 30–40 mol %. As the amount of the kinking component increased, the liquid crystallinity and the orientability of the polyesters from the melt decreased. Therefore, the level of tensile and flexural properties decreased. Very high plastic and tensile properties were only possible when the kink component was less than 10 mol %.
Introducing a substituent in the aromatic ring can cause a decrease in crystallinity and hence a drop of the melting point of the polyester. The substituents, especially asymmetrical substituents, can disturb the packing of the chain by inter-chain separation and by the random arrangements called internal copolymerization effect.
Different substituents, including halogens (Cl and Br), methyl, phenyl, and phenoxy, have been investigated for their effects on lowering the melting point. The size, the additional degrees of rotational and conformational freedom of the substituent has a great effect on how much the melting point can be lowered. This approach can also result in complete loss of LC behavior. If the percentage of the substituent is too high, this may disturb the packing and the polymer may lose all LC properties in the melt.
The “swivel” structure is shown below. Since the two phenylene rings are not in the same plane, they are twisted at a small angle with respect to each other, and the packing density of the polymer is lowered. The linkage “X” can be a direct bond, S, O, etc. Since the disturbing influence is along the backbone axis, the risk of losing LC properties is normally high, except in the case of a direct bond. This is due in part to the “kink” which is imparted by the O or S bond.
The simplest “swivel” structure is biphenol (BP), in which there is a direct linkage between the two rings. The liquid crystallinity of the polymers will not be completely lost even at 100 mol % of BP of the diols. The small twist angle of BP does have an effect on lowering the melting point. For example, Ekkcel I-2000 in which BP is one of the co-monomers, the melting point is more than 200° C. lower than homopolymer of HBA.
The common monomer used in this strategy is 6-hydroxy-2-naphthoic acid (HNA). The 2,6-naphthalene ring structure introduces a crankshaft structure in the polymer chain. After this modification, the melting points are lowered without sacrificing significant crystallinity since the backbone is still parallel to the original axis. Therefore, the LC properties and mechanical properties can be maintained even with a relatively high percentage of HNA monomer.
One of the most prominent high performance LCP polyesters developed was VECTRA®, derived from HNA and HBA. It is melt processable with common processing equipment capable of handling materials with melting points at 250–280° C. The excellent properties of VECTRA® polymers make them useful in a variety of applications such as optical fiber cables, fishing line and high strength fiber reinforced composites, etc.
From the discussion above, we can see that the introduction of “swivel” and “crankshaft” structures into the backbone of LC polymers are two of the best strategies to achieve low melting point for main chain LC polyester while maintaining excellent mechanical and thermal properties. Therefore, in order to obtain even better tractability and excellent mechanical properties, and investigate their structure-property relationships, wholly aromatic LC polyesters containing a phenylene-naphthalene structure would be desirable.
Although some compounds containing the phenylene-naphthalene structure have been reported, no polymers containing this subunit have been described in the scientific or patent literature. 2-(4-Hydroxyphenyl)naphthalene-6-carboxylic acid is disclosed in U.S. Pat. Nos. 5,151,549 and 5,146,025, but no description of any polymers prepare from the monomer appear in either patent.
Phenylene-naphthalene monomers are useful monomers for themotropic LC polyesters, as they may introduce additional dissymmetry into their monomers and polymers, combine the “crankshaft” and “swivel” effects together, and maintain wholly aromatic backbone structure. Therefore, better tractability can be achieved without sacrificing mechanical and liquid crystal properties.
SUMMARY OF THE INVENTION
It has been unexpectedly discovered that wholly aromatic thermotropic LC polyesters containing the phenylene-naphthalene moiety may be prepared from monomers of formula:
Copolyesters from these monomers exhibit superior physical and mechanical properties, including low melt temperatures.
DETAILED DESCRIPTION OF THE INVENTION
The wholly aromatic thermotropic LC polyesters of the present invention are composed of structural or repeating units of formula I, II, III, and/or IV.
The repeating units may be derived from any monomer having the phenylene-naphthalene structure and appropriate substituents, including COOH/OAc, COOPh/OH, and COOCH 3 /OAc. Acid/alcohol (COOH/OH) substituents are not considered appropriate, as reaction rates of such monomers are relatively low, and polymerization may result in a product that is contaminated with water. Particularly useful monomers are shown below. These are designated A-A, A-B, B-A and B-B, according to the acetoxy and carboxy substituents on the naphthalene and phenyl rings, respectively.
The LC polyesters may include repeating units in addition to those above, including those derived from monomers such as 4-hydroxybenzoic acid, 2-hydroxy-6-naphthoic acid, 4-aminobenzoic acid, 4-carboxy-4′ hydroxy-1.1′-biphenyl, terephthalic acid, isophthalic acid, phthalic acid, 2-phenylterephthalic acid, 1,2-naphthalene dicarboxylic acid, 1,4-naphthalenedicarboxylic acid, 2,6-naphthalene dicarboxylic acid and 4,4′-biphenyldicarboxylic acid or derivatives such as acetates or esters thereof. 4-Hydroxybenzoic acid, 2-hydroxy-6-naphthoic acid, terephthalic acid, and isophthalic acid are preferred comonomers. The LC polymers may also include end units derived from compounds such as resorcinol, hydroquinone, methyl hydroquinone, phenyl hydroquinone, catechol, 4,4′-dihydroxybiphenyl, and/or acetaminophen.
The LC polyesters may be prepared by any suitable condensation or step-growth polymerization process; however, melt polycondensation is a preferred method. Industrial processes for LC polymerization typically do not utilize direct esterification between diacid and diol monomers, because reaction rates can be slow, and it can be difficult to remove water completely, as noted above. Accordingly, preferred methods for the synthesis of LC polyesters are alcoholysis, esterolysis, acidolysis and phenolysis, as depicted in Scheme 1. The acidolysis method is used for the manufacture of many commercial main-chain LCPs. Acetic acid is released as the by-product.
In the phenolysis process, the phenyl ester of the aromatic acid is used instead of the aromatic acid. This reaction eliminates phenol as the by-product. Compared with acidolysis, the rate of the phenol formation is relatively slow, and it is more difficult to remove phenol than acetic acid. In the esterolysis method the acetate esters are used and methylacetate is the by-product. Alcoholysis uses readily available starting materials. Its by-product, methanol, is relatively non-toxic and easy to remove.
The polymerization may also be carried out in solution. High boiling solvents, such as Aroclor-7133, Therminol-66 and Marlotherm-S may be used as heat transfer fluids to carry out the transesterification reactions. This method can eliminate certain side reactions that may occur in melt polycondensation reaction. However, it may also change the morphology and/or thermal transition of the products. The polymers obtained from this method typically yield lower number- and weight-average molecular weights than those from the melt polycondensation reaction.
For the acidolysis method, diacetate derivatives of the aromatic diol and/or acetoxy derivatives of the aromatic acids are reacted with aromatic dicarboxylic acids in the melt. The polymerization temperature is typically between 250° C. and 300° C., depending on different monomers. The condensation by-product in this reaction is acetic acid and is usually removed by distillation, then vacuumed at high temperature during the final stage of the polymerization. Catalysts for the reaction include acetates of sodium, potassium, magnesium, zinc, manganese, cobalt, and antimony (III) oxide.
In one embodiment, the present invention relates to a process for preparing a liquid crystal polymer. The process includes polymerizing one or more phenylene-naphthalene monomers selected from the group consisting of
and combinations thereof, and, optionally, one or more comonomers. The one or more comonomers may be 4-hydroxybenzoic acid, 2-hydroxy-6-naphthoic acid, terephthalic acid, isophthalic acid, hydroquinone, derivatives thereof or a combination thereof.
Monomers containing the phenylene-naphthalene structure may be synthesized by a Suzuki cross-coupling reaction, as shown in Scheme 2.
wherein R 1 and R 2 are independently carboxy, acyloxy, or hydroxy; and R 3 is hydroxy, alkoxy or aryl.
A preferred embodiment of this process is shown in Scheme 2A
wherein R 1 and R 2 are independently carboxy, acyloxy, or hydroxy; and R 3 is hydroxy, alkoxy or aryl. In particular, R 1 and R 2 may be carboxy and acetoxy, respectively, both acetoxy, or both carboxy.
Boronic acids are the common substrates in this reaction, along with aryl halides or triflates. Esters of boronic acids and arylboranes are also used. The most commonly used catalyst is tetrakis(triphenylphosphine) palladium(0). Other palladium catalysts have also been employed with success. This reaction requires bases during the coupling, and the best results are achieved with the use of a relatively weak base such as sodium carbonate. Other bases such as sodium hydrogen carbonate, triethylamine and thallium hydroxide are also effective. The suggested mechanism by Suzuki for this reaction is as follows: First, an oxidative addition of the catalyst to the aryl halide gives an intermediate Ar[Pd]X. Secondly, a transmetallation step yields a diarylated palladium moiety. Finally a reductive elimination from the diarylated palladium compound gives the biaryl product and the palladium(0) catalyst re-enters the catalytic cycle
The LC polymers of the present invention are useful as high-strength and high-modulus fibers, and as high-performance films and plastics, especially for injection molding applications.
EXPERIMENTAL
Material and Instruments
4-Methoxybenzene boronic acid and 4-carboxyphenyl boronic acid were purchased from Lancaster and Frontier Scientific, Inc. 2-Bromo-6-methoxynaphthalene was purchased from Lancaster and Aldrich. Triphenylphosphine (99%) was purchased from Lancaster. 1-Propanol, pentanone, acetic anhydride, palladium acetate and hydrobromic acid (48% water solution) were purchased from ACROS. All materials were used as received without purification.
Proton nuclear magnetic resonance spectra ( 1 H NMR) were recorded on a Varian 500 spectrometer and referenced with respect to residual solvent. Elemental analyses were carried out by Midwest Microlab, LLC, Indianapolis, Ind. 46250. GC-MS spectra were obtained by Shimadzu GCMS-QP5000 gas chromatograph mass spectrometer. IR spectra were obtained from a Bio-Rad FTS 3000MX Mid-IR Excalibur spectrometer. Melting points were measured in capillary with a Mel-Temp apparatus and the thermometer was not calibrated. Thermogravimetric analysis (TGA) tests were carried out on a Perkin-Elmer TGA 7 with N 2 purging at a heating rate of 20° C./min. Differential scanning calorimetry (DSC) tests were carried out on a Perkin-Elmer DSC 7 and a TA Instruments DSC 2920 with N 2 purging at a heating rate of 10° C./min. Melting points were recorded as peak temperatures. The liquid crystalline behavior of the compounds was studied using polarized microscopy (Nikon Eclipse E600) with crossed polarizers, equipped with a heating stage (Linkam THMS-600). The magnification used was normally 100 or 200×.
Synthesis of 2-methoxy-6-(4′-methoxyphenyl)naphthalene (DMPN)
In an 100 mL three-necked RB flask equipped with a magnetic bar, a condenser and a nitrogen gas inlet, 2-bromo-6-methoxynaphthalene (7.32 g, 30 mmol), 4-methoxybenzene boronic acid (4.86 g, 32 mmol) and 1-propanol (50 mL) were mixed and stirred at room temperature for approx. 30 min. Palladium acetate (0.02 g, 0.09 mmol), triphenylphosphine (0.07 g, 0.27 mmol), Na 2 CO 3 solution (2M, 18 mL, 36 mmol) and water (10 mL) were added and the mixture was refluxed for 1.5 h. When the mixture was still hot, 30 mL of water was added and the mixture was stirred and cooled to room temperature. The resultant crystals were filtered, washed with water and recrystallized from acetone to give the DMPN title compound as colorless flakes (6.86 g, 86%). mp 194–196° C. (DSC 196° C). 1 H NMR (500 MHz, CDCl 3 ) δ 3.88 (s, 3H), 3.95 (s, 3H), 7–8 (m, 10 H). IR (KBr) ν (cm − ): 3058 (Ph-H, w), 1028 (OCH 3 , s). Anal. Calcd for C 18 H 16 O 2 : C, 81.79; H, 6.10. Found: C, 81.80; H, 6.25. GC-MS (m/z) 264 (M + ).
Synthesis of 2-acetoxy-6-(4′-acetoxyphenyl)naphthalene (DAPN)
A mixture of DMPN (2.54 g, 10 mmol), hydrobromic acid (48% water solution, 40 mL) and acetic acid (40 mL) was purged with nitrogen and refluxed overnight. The mixture was poured into 200 mL of water and the resultant solid was filtered and dried. 2-Hydroxy-6-(4′-hydroxyphenyl)naphthalene was obtained as a light purple solid (2.20 g, 96%). The crude intermediate was stirred with 40 mL of acetic anhydride and 1–2 drops of sulfuric acid for 2 hours. The resultant pink solid was filtered and recrystallized from acetone to afford the title compound as light yellow crystals (2.75 g, 90%). mp 178–180° C. (solid-turbid liquid), 205–206° C. (clear point); DSC 182° C. and 207° C. 1 H NMR (500 MHz, CDCl 3 ) δ 2.29 (s, 3H), 2.33 (s, 3H), 7.2–8.3 (m, 10H). IR (KBr) ν (cm −1 ): 1755 (C═O, s), 1368 (CH 3 CO, s), 1200–1249 (O—C—O, s). Anal. Calcd for C 20 H 16 O 4 : C, 74.99; H, 5.03.
Found: C, 74.88; H, 5.02. GC-MS (m/z) 320 (M + ).
Synthesis of 2-(4′-carboxyphenyl)-6-methoxynaphthalene (CMPN)
In an 100 mL three-necked RB flask equipped with a magnetic bar, a condenser and a nitrogen gas inlet, 2-bromo-6-methoxynaphthalene (4.74 g, 20 mmol), 4-carboxybenzene boronic acid (3.50 g, 20 mmol) and 1-propanol (40 mL) were mixed and stirred at room temperature for approximately 30 min. Palladium acetate (0.014 g, 0.003 equiv., 0.06 mmol), triphenylphosphine (0.047 g, 0.009 equiv., 0.18 mmol), Na 2 CO 3 solution (2M, 12 mL, 1.20 equiv., 24 mmol) and water (8 mL) were added and the mixture was refluxed for 1.5 h. When the mixture was still hot, 25 mL of water was added and the mixture was stirred and cooled to room temperature. The resultant crystals were filtered, washed with water and refluxed with 50 mL of acetic acid for 3–4 h. A white solid was obtained (5.08 g) and recrystallization from acetone showed the title compound as white crystals (4.63 g, 83%). mp 288–289° C. 1 H NMR (500 MHz, DMSO) δ 3.90 (s, 3H), 7.2–8.3 (m, 10H), 12.99 (s, 1H). IR (KBr) ν (cm −1 ): 2500–3000 (COO—H, very broad, m), 1030 (OCH 3 , s), 1678 (C═O, s). Anal. Calcd for C 18 H 14 O 3 : C, 77.68; H, 5.07. Found: C, 77.56; H, 5.08.
Synthesis of 2-(4′-carboxyphenyl)-6-acetoxynaphthalene (CAPN)
A mixture of CMPN (2.78 g, 10 mmol), hydrobromic acid (48% water solution, 80 mL) and acetic acid (150 mL) was purged with nitrogen and refluxed for 48 hours. The mixture was then poured into 400 mL of water and the resultant purple solid was filtered and dried (2.58 g, 98%). The crude intermediate was stirred with 40 mL of acetic anhydride and 1–2 drops of sulfuric acid for 2 hours. The resultant solid was filtered (2.88 g) and recrystalization from acetone or pentanone afforded the title compound as light yellow crystals (2.02 g, 66%). mp 254–256° C. (DSC 262° C.). 1 H NMR (500 MHz, DMSO) δ 2.34 (s, 3H), 7.3–8.4 (m, 10H), 13.02 (s, 1H). IR (KBr) ν (cm −1 ): COO—H (2800–3100, broad, m), 1685 (C═O, s), 1225 (C—O—C, vs), 1365 (CH 3 CO, s). Anal. Calcd for C 19 H 14 O 4 : C, 74.50; H, 4.61.
Found: C, 74.28; H, 4.59.
Synthesis of 6-(4′methoxyphenyl)-2-naphthoic acid (MCPN)
In an 100 mL three-necked RB flask equipped with a magnetic bar, a condenser, and a nitrogen gas inlet, 6-bromo-2-naphthoic acid (2.62 g, 96%, 10 mmol), 4-methoxy-benzeneboronic acid (1.52 g, 10 mmol) and 1-propanol (20 mL) were mixed and stirred at room temperature for about 30 min. Palladium acetate (0.007 g, 0.003 equiv., 0.03 mmol), triphenylphosphine (0.024 g, 0.009 equiv., 0.9 mmol), Na 2 CO 3 solution (2 M, 8 mL, 1.20 equiv., 12 mmol) and water (4 mL) were added and the mixture was refluxed for 2 h. When the mixture was still hot, 20 mL of water was added and the mixture was stirred and cooled to room temperature. The resultant crystals were filtered, washed with water and refluxed with 50 mL of acetic acid for 3–4 h. A white solid was obtained (2.55 g) and recrystallization from acetone gave the title compound as white crystals (2.24 g, 81%): mp 267–269° C.
1 H NMR (500 MHz, DMSO) δ 3.83 (s, 3H), 7.0–8.6 (m, 10H), 13.03 (s, 1H). IR (KBr) ν (cm −1 ): 2800–3100 (PhCOO—H, broad, m), 1690 (C═O, s), 1034 (OCH 3 , s). Anal. Calcd for C 18 H 14 O 3 : C, 77.68; H, 5.07. Found: C, 77.41; H, 5.02.
Synthesis of 6-(4′-acetoxyphenyl)-2-naphthoic acid (ACPN)
A mixture of MCPN (2.78 g, 10 mmol), hydrobromic acid (48% water solution, 80 mL) and acetic acid (150 mL) was purged with nitrogen and refluxed for 48 hrs. The mixture was then poured into 400 mL of water and the resultant purple solid was filtered and dried (2.53 g, 96%). The crude intermediate was stirred with 40 mL of acetic anhydride and 1–2 drops of sulfuric acid for 2 hours. The resultant solid was filtered (2.91 g) and recrystallization from acetone or pentanone afforded the title compound as light yellow crystals (2.18 g, 71%). mp 256–258° C. (DSC 260° C.). 1 H NMR (500 MHz, DMSO) δ 2.31 (s, 3H), 7.2–8.7 (m, 10H), 13.1 (s, 1H). IR (KBr) ν (cm −1 ): 2800–3100 (PhCOO—H, broad, m), 1686 (C═O, s), 1364 (CH 3 CO, s). Anal. Calcd for C 19 H 14 O 4 : C, 74.50; H, 4.61. Found: C, 74.53; H, 4.59.
Synthesis of 2-carboxy-6-(4′-carboxyphenyl)naphthalene (DCPN)
In an 100 mL three-necked RB flask equipped with a magnetic bar, a condenser and a nitrogen gas inlet, 6-bromo-2-naphthoic acid (2.51 g, 10 mmol), 4-carboxybenzene boronic acid (1.66 g, 10 mmol) and 20 mL of 1-propanol were mixed and stirred at room temperature for about 30 min. Palladium acetate (0.007 g, 0.003 equiv., 0.03 mmol), triphenylphosphine (0.024 g, 0.009 equiv., 0.9 mmol), Na 2 CO 3 solution (2 M, 8 mL, 1.20 equiv., 12 mmol) and water (4 mL) were added and the mixture was refluxed for 1.5 h. When the mixture was still hot, 20 mL of water was added and the mixture was stirred and cooled to room temperature. The solid was separated by filtration and refluxed with 2 mL of 1M HCl and 25 mL of acetic acid. A white solid was obtained after filtration. No melting point was detected up to 350° C. 1 H NMR (500 MHz, DMSO) δ 7.9–8.7 (m, 10H), 13.1 (s, 2H). IR (KBr) ν (cm −1 ): Anal. Calcd for C 18 H 12 O 4 : C, 73.97; H, 4.14. Found: C, 73.59; H, 4.05.
Suzuki Coupling Reactions
The reaction conditions of Huff et al.( Org. Synth. 1988, 75, 53–60) were used in our coupling reactions. The reactions were carried out in 1-propanol and water. Sodium carbonate was used as the base, and triphenylphosphine and palladium acetate were used to generate Pd(0) in situ. The temperature was around 100° C. for refluxing. Typically, reactions were completed within one hour. The solution was dark red-orange in color at the end of the reaction and the products were precipitated from the solution even at refluxing temperature. After cooling to room temperature, the mixture was filtered and washed with water to give crystals or powders. For compounds containing an acid group, the resultant products were sodium salts of the acid. Acidification with acetic acid gave the acid products. The results are summarized in Table 2.
An easy and common way to cleave the aryl methyl ether group is by refluxing the substrates overnight in hydrobromic acid solution. This method worked well for the A-A monomer (Scheme 3). For A-B or B-A monomers, the solubilities are much lower than the A-A monomer and extended reaction times (24–48 hours) were required to complete the demethylation process. From the NMR spectra, the uncleaved compound was less than 3% in the crude product. The yields were very good (above 95%). These cleaved compounds were used in the next step after workup without further purification.
TABLE 2
A—A
A-B
B-A
B—B
R 1
OMe
OMe
COOH
COOH
R 2
OMe
COOH
OMe
COOH
Yield *(%)
85–90
80–85
80–85
75–80
*Isolated yield after recrystallization
The acetylation reaction was carried out in acetic anhydride with sulfuric acid as catalyst. The reactions were performed at room temperature or at 40–50° C. for 2–3 hours. The yields were nearly quantitative.
The resultant products were usually pink powders, and recrystallization gave fine, light yellow or pink crystals. The structures of pure products were confirmed by NMR, IR, GC-MS and elemental analysis. For the A-A monomer, the GC-MS showed a molecular ion peak with m/z=320 (EI), which matched the calculated molecular weight of the molecule.
Almost all the monomers and intermediates showed liquid crystal phases when heated. The liquid crystal properties were investigated by capillary melting test, DSC and cross polarized microscope. Transition temperatures were determined by the peak temperatures from DSC curves. The data is listed in Table 3 (Cr=crystal, N=nematic, I=isotropic liquid).
TABLE 3
Structures and transition temperature for monomers
Sample ID
Structures
Transition Temperature
Shao-01-01
Cr 196 I(I 187 N 142 Cr)
Shao-01-06
Cr 288 N 338 I
Shao-02-27
Cr 296 N 322 I
Shao-01-10
Cr 269 N 339 I
Shao-01-46
Cr 316 N 416 I
Shao-01-21
Cr 182 N 207 I
Shao-01-18
Cr 270 I
Shao-01-54
Cr 263 N→polymerization
Shao-01-63
Cr 260 N→polymerization
Shao-01-16
No melting point was detectedup to 350° C.
2-methoxy-6-(4′-methyoxyphenyl)naphthalene (Shao-01-01) did not show any liquid crystal phase during heating process, however nematic phase was observed during cooling (monotropic liquid crystalline phase). The A-A monomer (Shao-01-21) melted at around 180° C. into a turbid liquid (nematic liquid crystal phase), and turned into a clear liquid at 206° C. A-B and B-A monomers (Shao-01-54 and Shao-01-63) melted to nematic phase, however the clearing point was not observed up to decomposition temperature because the polymerization occurs at higher temperatures. The B-B monomer's melting point was very high and was not observed up to 350° C. However, under fast heating rate (40° C./min), an endothermal peak was observed on the DSC curve at around 420° C., which is quite above its decomposition temperature.
Some of the DSC curves of the monomers showed two endothermal transition peaks when heated. The enthalpies for the second peaks (clearing points) were much smaller than that for the first peaks (melting points).
Under polarized light microscope, threaded textures were commonly observed when the monomers melted. These textures are typical textures for nematic liquid crystalline phases.
The thermal stability of all monomers was investigated by TGA at a heating rate of 20° C./min under N 2 atmosphere. The temperature at 5% and 10% weight loss were used to characterize the thermal stability and the results are summarized in Table 4.
TABLE 4
TGA data of monomers
5% weight loss
10% weight loss
Sample ID
temperature (° C.)
temperature (° C.)
Shao-01-01
182
199
Shao-01-06
220
233
Shao-01-10
253
270
Shao-01-21
195
208
Shao-01-54
230
250
Shao-01-63
240
257
The entropy and enthalpy changes at transition temperatures (at Tg and Tm) are measured or calculated from DSC curves and listed in Table 5.
TABLE 5
Entropy and enthalpy at transitions for monomers
At Melting Point
At Clearing Point
ID
Structures
(J/g)
(J/g)
Shao-01-01
ΔH = 130.2ΔS = 0.28
N/A
Shao-01-06
ΔH = 113.8ΔS = 0.20
ΔH = 26.2ΔS = 43 × 10 −3
Shao-01-27
ΔH = 84.7ΔS = 0.15
ΔH = 4.8ΔS = 8.1 × 10 −3
Shao-01-10
ΔH = 102.8ΔS = 0.19
ΔH = 19.0ΔS = 31 × 10 −3
Shao-01-46
ΔH = 96.8ΔS = 0.16
ΔH = 2.1ΔS = 3.0 × 10 −3
Shao-01-21
ΔH = 111.7ΔS = 0.22
ΔH = 3.5ΔS = 7.5 × 10 −3
Shao-01-18
ΔH = 100.8ΔS = 0.19
N/A
Shao-01-54
ΔH = 87.7ΔS = 0.16
N/A
Shao-01-63
ΔH = 72.1ΔS = 0.13
N/A
Compared to other monomers with the same functional groups but different core structure, we can see that as the rigid rod length increases, the LC temperature range also increases (Table 6 and Table 7). An interesting point is that CMPN and MCPN have almost the same clearing temperature (338 and 339° C.), indicating that the LC phase stabilities are almost the same for these two compounds. However, the melting point of MCPN is nearly 20 degrees lower than CMPN.
TABLE 6
Transition temperatures for some monomers
Transition Temperatures
Monomers
Structures
(° C.)
6-methoxy-2-naphthoic acid
Cr 206 N 219 I
4′-methoxy-4-carboxybiphenyl
Cr 258 N 300 I
2-(4′carboxyphenyl)-6-methoxy naphthalene(CMPN)
Cr 288 N 338 I
6-(4′-carboxyphenyl)-2-naphthoic acid (MCPN)
Cr 269 N 339 I
For the diacetoxy compounds in Table 7, the similar effect was observed. When the core structures are naphthalene and biphenyl, the molecules do not show any liquid crystalline behavior. The phenylene-naphthalene structure monomer began to show nematic phase by providing longer rigid rod length. However, when compared to symmetric monomer 6,6′-diacetoxy-2,2′-bianphthyl, both the melting point and clearing point of dissymmetric phenylene-naphthalene monomer were much lower.
TABLE 7 Transition temperatures for some monomers Transition Temperatures Monomers Structures (° C.) 2,6-diacetoxynaphthalene Cr 175 I 4,4′-diacetoxybiphenyl Cr 161 I 2-acetoxy-6-(4′-acetoxyphenyl)naphthalene(DAPN) Cr 182 N 207 I 6,6′-diacetoxy-2,2′-binaphthyl Cr 246 N 304 I
Materials and Instruments—Synthesis of Polymers
Potassium acetate (KOAc), tin (II) trifluoromethane sulfonate ((CF 3 SO 3 ) 2 Sn), phenyl acetate, pentafluorophenol (PFP) and pentafluorobenzene (PFB) were purchased from Acros. Tetrachloroethylene (TCE) was purchased from Aldrich. 2-acetoxy-6-naphthoic acid (ANA), 4-acetoxy benzoic acid (ABA) were purchased from Proctor. Benzoic acid was purchased from Fisher. 6-Acetoxy-2-naphthoic acid (ANA), 4-acetoxybenzoic acid (ABA) were purchased from Proctor. Terephthalic acid (TA) was purchased from Amoco. A heat transfer fluid, Therminol 66, was obtained from Solutia, Inc. The dispersing agent, Ganex V-220, was obtained from ISP Tehnologies, Inc. All materials were used as received without purification.
GC-MS spectra were obtained on a Shimadzu GCMS-QP5000 gas chromatograph mass spectrometer. TGA tests were carried out on a Perkin-Elmer TGA 7 with N 2 purging at heating rate of 20° C./min. DSC tests were carried out on a Perkin-Elmer DSC 7 and a TA Instruments DSC 2920 with N 2 purging at a heating rate of 10–20° C./min. Some samples were tested on Mettler-Toledo DSC 822e at a heating and cooling rate of 20° C./min. Thermo mechanical analysis (TMA) tests were carried out on a Perkin-Elmer TMA 7 with He purging at a heating rate of 10° C./min. The liquid crystalline behavior of the compounds was studied using polarized microscopy (Nikon Eclipse E600) with crossed polarizers, equipped with a heating stage (Linkam THMS-600). The magnification used was 100 or 200×.
Synthesis of Polyesters: Bulk Polymerization
The monomers and approximately 500 ppm of KOAc were charged into a polymerization tube with a side branch. The system was degassed and purged with nitrogen three times. While purging with nitrogen, the temperature was increased to 250° C. for about 1.5 h, 280° C. for 30 min, 300° C. for 30 min, and 320° C. for 30 min. During the temperature gradient, acetic acid was collected in a test tube at the end of the side branch. At the final stage, while the reaction temperature was kept at 320–330° C., the side branch was sealed and vacuum was slowly conducted for 30–60 min to remove the acetic acid byproduct.
In most cases, the monomers melted at 220–230° C., and polymerization occurred with the evolution of acetic acid at around 250° C. After cooling to room temperature, the reaction vessel was broken and the resultant polymer was collected.
Synthesis of Polyesters: Non-Aqueous Dispersion Polymerization
In an 100 mL RB flask, the monomers (for an example, 0.612 g of CAPN, 0.540 g of ABA) and the catalyst (500 ppm) were mixed with dispersing agent, Ganex V-220 (0.045 g), and heat transfer oil, Therminol 66 (8.0 ml). The mixture was heated to 220–250° C. for about 2 h with N 2 purging and stirring. The temperature was then increased to 280° C. for 30 min, 300° C. for 30 min and 320° C. for 30 min.
After cooling to room temperature, the resultant polymer (powder solid) was isolated and extracted with hexane overnight and dried.
Inherent Viscosities of Polymers
Inherent viscosities (IV's) of polymers were measured in PFP/PFB mixed solution (w/w=1.46/1) at 30° C. with an Ubbelohde viscometer. The weighed polymer was dissolved in heated PFP. PFB was added and mixed completely. IV's were measured at a polymer concentration of approximately 0.2 g/dL in the mixed solvent system. The solution was filtered with a 1 μm filter before filling the viscometer.
Results and Discussion: Synthesis of Polyesters
Effect of Catalyst—KOAc and Sn(OTf) 2
For the polymerization, two different catalysts were studied with the model reaction of esterification of benzoic acid and phenyl acetate at 150° C. to compare their efficiency (Scheme 3.2). One catalyst is KOAc, which is commonly used in industry. The other is Sn(OTf) 2 , is reported to be efficient for polymerization of lactones at low temperature. The concentration of the catalyst was 500 ppm. The two starting materials were charged into the flask at 1:1 ratio with the catalyst, and the reaction mixture was heated to 150° C. under stirring. The reaction was monitored by GC-MS at 1 hr, 2 hr and 4 hr.
The results from these two catalysts are listed in Table 8. After four hours, the product peak was still very small for the reaction that used KOAc as the catalyst. For the reaction using (CF 3 SO 3 ) 2 Sn as the catalyst, the product peak was quite large after only one hour. After 4 hr at 150° C., conversion of starting materials to phenyl benzoate was greater than 95%. Therefore, the preliminary study demonstrated that (CF 3 SO 3 ) 2 Sn is an effective catalyst for the acidolysis reaction and is effective at lower temperatures (150° C.) than the commonly used KOAc.
However, at higher temperatures (250° C., the starting polymerization temperature), it was difficult to operate the polymerization with the tin catalyst. The high activity of the tin catalyst at low temperatures causes premature homopolymerization of the lower melting monomer. 4-Acetoxybenzoic acid melts at 187° C. and 2-acetoxy-6-naphthoic acid melts at 228° C. Thus, melting of the lower melting point monomer in the presence of a catalyst active at low temperatures can induce significant homo-polymerization. Blocky structures can be formed and, in some cases, the melting points of the oligomers formed may increase beyond the polymerization temperature, causing solidification of the polymerization mixture. For the system using KOAc as the catalyst, significant polymerization began at around 250° C. At this temperature the starting materials are a well mixed solution. KOAc is easy to use in high temperature polymerizations and was used in subsequent polymerizations. However, the tin catalyst may be useful when used in lower concentrations.
TABLE 8 Catalyst effect for model reaction Catalyst After 1 hour After 2 hours After 4 hours No catalyst Only starting material Only starting material Only starting material peaks peaks peaks KOAc Only starting material Small product peak Small product peak peaks Area p /Area a = 0.006 Area p /Area a = 0.017 (CF 3 SO 3 ) 2 Sn Big product peak Big product peak Big product peak Area p /Area a = 7.2 Area p /Area a = 13.7 Area p /Area a = 28.7 Area p : the peak area of product, M/Z = 198 (M + ) Area a ; the peak area of benzoic acid, M/Z = 122 (M + )
Polymerization Method
Two different polymerization methods were studied: bulk polymerization and non-aqueous dispersion polymerization.
(I) Bulk Polymerization Without Stirring
The bulk polymerization was conducted in a polymerization tube with a side branch. Usually monomers melted at 220–250° C. to form a clear yellow solution. Polymerization occurred around 250° C. and acetic acid distilled out of the reaction. Some sublimation of the monomer was observed at the beginning as the vapor condensed on the glass tube and the solid was washed down by the refluxing acetic acid. The bubbling action of the acetic acid helped with the mixing of the monomers. The polymerization tube was also shaken occasionally to ensure that a good mixture formed. For some compositions, the mixture solidified during the later stages of polymerization due to the high melting point of the products.
A Vectra-type LCP (HBA/HNA=58/42) were synthesized using this procedure as a control experiment. IV's as high as 5.1 were measured (usually the commercial VECTRA® has an IV around 5.0), which demonstrated that this method worked very well for this polymerization and produced high molecular polyester. IV's ranging from 1.8 to 6.7 dL/g were obtained for the soluble polymer compositions investigated in this thesis.
(II) Non-aqueous Dispersion Polymerization
Non-aqueous dispersion polymerization was also studied as a method to produce polyesters, with Therminol 66 synthetic heat transfer fluid as a dispersion medium. This is made from hydrogenated terphenyls and polyphenyls, and offers outstanding high-temperature performance up to 345° C. Ganex V-220 was used as a dispersing agent.
All of the starting materials were stirred and heated in a 3-necked round bottom flask. The mixture turned into a clear orange solution at approximately 250° C., and after 30–40 mins of polymerization, some powder began to participate from the solution and the mixture became cloudy. For some reactions, the polymer stuck to the magnetic stirring bar. The final product was usually a grey powder and was washed by hexane.
The TGA curves for the polymer showed two main weight losses. One of them was around 250° C., which indicated that the polymerization was not completed. One possible reason for this is that a vacuum stage was not used for this reaction and the complete removal of acetic acid needed even higher temperatures or longer times. DSC curves for the products were inconsistent, which may be caused by the incomplete removal of the heat transfer fluid or dispersing agent. Therefore, this method was not chosen for polymer synthesis.
Molecular Weight and Solubility of Polymers
Most of the synthesized polyesters are not soluble in any organic solvent, even hot pentafluorophenol (PFP). The best solubility was obtained from HNA/TA/DAPN co-polyesters. When the polyesters from this series had a melting point lower than 260° C., solubility in PFP/PFB mixed solvent was obtained. When the polymer had a higher melting point it was not soluble, although many polymers could still be swollen in heated pure PFP. The solubility of many polymers incorporating phenylene-naphthalene structures was lower than the commercial VECTRA® polymers. The majority of the polymers synthesized in this thesis were not soluble in hot PFP.
The inherent viscosity (IV) data for all soluble copolymers ranged from 1.8 to 6.7 dL/g, which is in the same range of VECTRA® polymers (approximately 3–5). This indicated that the polyesters were prepared with relatively high molecular weights. It was also found that higher IVs were obtained from A-B or B-A systems rather than the A-A or B-B systems, which was also true for VECTRA® polyesters. The stiochiometry is easier to control in A-B and B-A systems, which might be the reason for higher IV values. Alternatively, chain stiffness and the corresponding Mark-Houwink constants may vary in these systems, which would cause different IV values for the same molecular weights.
Thermal Properties of Polyesters
Polyesters from A-A Monomer
A-A monomer (DAPN) was copolymerized with HBA and TA to give a hard and brittle brown solid, which was not soluble in common solvents. The molar percentage of DAPN was between 15-30%. The thermal property results from the polyesters are listed below (Table 9). Most of the polymers were not soluble even in hot PFP, and the only soluble polymer (HBA/TA/DAPN=45/27.5/27.5) had an IV of 1.8 dL/g. One possible reason for its higher solubility may be the lower molecular weight, as indicated by the IV. The thermal stability for these polyesters was very good with most of the decomposition temperatures above 420° C.
TABLE 9
Properties of HBA/TA/DAPN copolyesters
Composition
IV a
5% weight
10% weight
Sample ID
HBA/TA/DAPN
(dL/g)
loss T(° C.)
loss T(° C.)
Tg(° C.)
Tm(° C.)
Shao-01-120
75/15/15
NS
460
480
—
387
Shao-01-109
60/20/20
NS
450
470
—
358
Shao-01-67
50/25/25
NS
430
460
110~120
347
Shao-02-58
45/27.5/27.5
1.8
420
440
115~120
353
Shao-02-170
45/27.5/27.5
NS
439
455
—
351
Shao-01-152
40/30/30
NS
420
460
—
346
Shao-02-174
36/32/32
NS
407
442
—
352
Shao-02-79
35/32.5/32.5
NS
415
435
—
372
Shao-01-118
30/35/35
NS
450
480
—
390
a IV was obtained in pentaflorophenol and pentaflorobenzene mixture at 30° C.
b NS means not soluble in the mixed solvent
The melting points (Tm) of this series of polymers were relatively high. The lowest melting point was above 340° C., which was obtained with 30% DAPN. Either increasing or decreasing DAPN from 30% will generate higher Tm for the copolymers. Glass transition temperatures (Tg) were not obvious on the DSC curves, and the shape of melting peak appeared quite similar to VECTRA® polymers, which was broad and small.
Some of the copolyesters were selected for annealing studies at 250° C. and 280° C. at different times. After annealing, the sample was retested by DSC. The results showed no significant change for these curves. The melting points shifted slightly to higher temperatures (less than 10° C.), and the shape looked slightly sharper. After annealing at higher temperature (280° C.), these effects became more pronounced. At longer annealing times, the melting peaks split into two clearly defined peaks, which indicated that the polymers have two different transition processes. Previous reports about VECTRA® polymers referred to these two transitions as slow transition and fast transition. It was also reported that the high melting peak remained at the same temperature, which was independent of annealing time while the low melting peak shifted to a higher temperature with increasing annealing time and the enthalpy increased as well. This was also true for the polyesters studied in this project.
Surprisingly, when the HBA monomer was replaced by HNA, the melting points of the polyesters dropped dramatically, to even lower than 240° C. (Table 10). The lowest melting point was obtained with 17% DAPN as co-monomer. Compared to the curve of HNA/TA/HQ, the minimum melting point is 50–60 degrees lower. Surprisingly, some low melting point compositions displayed sharp melting peaks. Furthermore, the solubility of the polyesters improved greatly and most of the compositions could be dissolved or swelled in the mixed solvent of PFP and PFB. Only polyesters having high DAPN composition (>30%) did not dissolve at all.
TABLE 10
Properties of HNA/TA/DAPN copolyesters
Composition
IV a
5% weight
10% weight
Sample ID
HNA/TA/DAPN
(dL/g)
loss T(° C.)
loss T(° C.)
Tg(° C.)
Tm(° C.)
Shao-02-159
74/13/13
Swells
424
436
116
322
Shao-02-146
70/15/15
Swells
418
431
111
307
Shao-02-158
66/17/17
2.3
418
438
109
230
Shao-02-145
60/20/20
3.4
416
432
112
233
Shao-02-161
56/22/22
3
430
444
112
235
Shao-02-144
50/25/25
2.9
420
435
113
259
Shao-02-147
40/30/30
NS b
430
445
113
326
Shao-02-149
30/35/35
NS
426
448
112
380
a IV was obtained in pentaflorophenol and pentaflorobenzene mixture at 30° C.
b NS means not soluble in the mixed solvent
The thermostability for these polymers was high, with decomposition temperatures varying at only a narrow range for the different compositions (418–430° C.).
From the DSC curves, an obvious glass transition (Tg) can be observed at approximately 110–120° C., which is quite similar to the Tg of commercial VECTRA®) (110–115° C.). The enthalpy change at the melting point was between 1.3–2.2 J/g. The obvious Tg transition indicated that compared to the HBA/TA/DAPN copolyesters, HNA/TA/DAPN copolyesters have a much higher percentage of amorphous structure. This is consistent with the higher solubility and lower melting points. All of this information suggests that HBA structure packs much better than HNA structure with the DAPN structure.
Polyesters from B-A Monomer
The B-A monomer (ACPN) was copolymerized with HBA or HNA, respectively. Similar to the previous series, the copolymers from HNA have much lower melting points than those of the HBA copolymers. The properties of HNA/ACPN copolyesters were summarized in Table 11. The compositions of ACPN were between 25–35 mol %, and most of the polymers have high decomposition temperatures (above 420° C.). Only one polymer was soluble in the mixed solvent of PFP/PFB, and an IV of 6.7 dL/g was obtained. This IV is much higher than the polymers from A-A monomer, possibly due to the better 1:1 stiochiometric ratio in A-B system than A-A/B-B system, thus producing higher molecular weight polymers.
TABLE 11
Properties of HNA/ACPN copolyesters
Composition
IV a
5% weight
10% weight
Sample ID
HNA/ACPN
(dL/g)
loss T(° C.)
loss T(° C.)
Tg(° C.)
Tm(° C.)
Shao-02-137
75/25
— b
378
394
—
352
Shao-02-105
70/30
6.7
425
438
—
268
Shao-02-244
67.5/32.5
NS c
373
385
—
270
Shao-02-115
65/35
NS
420
432
—
268
Shao-02-107
60/40
—
426
440
—
260
Shao-02-118
55/45
—
430
445
—
273
Shao-02-109
50/50
NS
420
436
—
276
Shao-02-110
40/60
—
425
438
—
301
a IV was obtained in pentaflorophenol and pentaflorobenzene mixture at 30° C.
b — means solubility was not attempted
c NS means not soluble
The melting points of these polymers were between 260° C. to 350° C. The lowest melting point (˜260° C.) was obtained with approximately 37 mol % ACPN monomer. Compared with the HNA/HBA curves, the shape of the melting point-composition curve is sharper, and the lowest melting point also shifted to lower compositions of ACPN%. The melting peaks shown on DSC curves were broad, similar to Vectra's melting peak. The average enthalpy change at Tm was around 2.8 J/g, which is larger than the previous series. Tg was not clearly detectable on the DSC curves.
The next series of polymers investigated were the HBA/ACPN copolyesters. The experiental data are shown in Table 12. Interesting DSC curves were obtained when the HNA monomer from the previous series was replaced by the HBA monomer. A large sharp endothermal peak was observed between 200–210° C. for the HBA/ACPN copolyesters. This peak appeared for most of the compositions, except for those with ACPN>80%. For ACPN=70%, the first endothermal peak was very small. Analysis by hot-stage microscopy showed that a fluid phase was not formed at these temperatures. In fact, changes in the sample could not be detected optically or by shearing the cover slip over the powdered sample.
TABLE 12
Properties of HBA/ACPN copolyesters
Composition
IV
5% weight
10% weight
Sample ID
HBA/ACPN
(dL/g)
loss T(° C.)
loss T(° C.)
Tg(° C.)
Tm(° C.)
Shao-02-88
70/30
NS a
395
408
214
391
Shao-02-95
65/35
— b
415
425
208
386
Shao-02-94
60/40
—
405
420
209
384
Shao-02-89
50/50
NS
430
445
206
373
Shao-02-263
45/55
345
380
198
363
Shao-02-99
40/60
—
410
420
206
366
Shao-02-265
30/70
—
380
408
195
353
Shao-02-103
30/70
—
420
435
181
343
Shao-02-266
25/75
—
390
411
197
357
Shao-02-163
20/80
—
417
445
—
381
Shao-02-181
10/90
—
428
452
—
383
Shao-02-258
0/100
—
400
417
—
383
a NS means not soluble
b — means solubility was not attempted
After several tests by different techniques, such as x-ray, DSC and dielectric measurements, it was concluded that the transition was a crystal-crystal transition. It is obvious that this temperature is still far above the sharp endothermal peak temperature (200˜220° C.) found in this work. At the low molecular end of the oligomers studies, the tetramer of HBA had a melting point of 260° C.
Since a Tg transition was not observed around 100–120° C., the possibility that the 200–210° C. peak represented the Tg was investigated. Wunderlich et al. have reported on hysteresis effects in polymer glasses that can lead to glass transition temperatures, which appear as endothermal “peaks” in the DSC curves. The appearance of the Tg is often a complex function of the thermal history of the polymer sample. Generally, the “peak” appearance results from a superheated glass that moves quickly toward equilibrium as soon as the time scale of the heating permits. DSC tests were performed at different heating rates for Shao-02-88, which had the composition of HBA/ACPN=70/30. As the heating rate decreased, the endothermal peak became decreasingly smaller. This behavior is consistent with hysteresis effects seen in polymer glasses at Tg.
This polyester was also heated to 400° C. and dropped immediately into dry ice. The quenched sample was checked by DSC test again at 10° C./min. Because of the rapid cooling rate, the polymer chains do not have time for better packing, and more amorphous phase forms. The quenched sample showed a typical Tg transition at around 200° C.
An annealing study for this polymer was also performed at 300° C. for 12 hours. After annealing, the first endothermal peak shifted slightly to lower temperature, and the entropy was smaller (ΔH=7.25 J/g→6.36 J/g) than the sample without annealing. Meanwhile, the melting peak became larger ((ΔH=2.8 J/g→4.1 J/g), as compared to the unannealed polymer. Annealing of other compositions gave similar results. The annealing usually increases the crystallinity of the polymer.
DMTA is a sensitive method to detect Tg transitions. The storage modulus will decrease and the loss factor, tan δ, will show a peak at the Tg transition. However, since the melting point for these copolyesters was around 400° C., it was difficult to make coherent film from hot pressing. A sample of thickness around 0.8–1 mm was obtained from hot pressing and subjected to TMA testing. The analysis was conducted in penetration mode under a static force of 50 mN at a heating rate of 10° C./min. There are two important results from this test. First, it is quite evident that there is not a Tg in the 100–120° C. range where most wholly aromatic polyesters show a Tg. Second, the penetration result seen at >200° C. is strongly indicative of the Tg.
A TMA expansion test was also conducted with a static force of 0 mN at a heating rate of 10° C./min. There are three different slopes on the curves. The initial slope is about 4×10 −3 , and after the Tg transition (220–230° C.), the slope changed to approximately 1×10 −4 . The final slope on the curve increased to about 0.8. These results are consistent with the current assignments of the Tg and Tm in the copolyester series.
In conclusion, a combination of thermal methods demonstrated that the sharp endothermal peak at approximately 210° C. is a Tg transition. The Tg transition temperatures from these methods were in good agreement with each other (200–230° C.). Most surprisingly, this Tg assignment is almost 100° C. higher than reported for other wholly aromatic polyesters.
A melting point-composition diagram for this series indicates that as the content of the ACPN monomer increased, the melting point of the copolyemers decreased, typical of the eutectic behavior observed in LC polyesters. However, the polyester melting points increased abruptly at ACPN concentrations above 70 mol % and remained constant at 383° C.
Polyesters from A-B Monomer
A-B monomer (CAPN) was copolymerized with HBA and HNA, respectively. Similar to the B-A monomer, the copolymers with HNA have much lower melting points than the HBA copolymers. The polyesters from HNA/CAPN have similar thermal properties to HNA/ACPN copolymers, i.e., a minimum melting point at approximately 260° C. (Table 13) with a CAPN composition around 35%. Compared with HNA/HBA copolymers, the shape of the curve is quite similar, and the only difference is that the minimum melting point was achieved with lower ACPN % than HBA %. Select samples were subjected to solubility testing, but were not soluble in hot PFP. Therefore, IV data was not obtained.
TABLE 13
Properties of HNA/CAPN copolyesters
Composition
5% weight
10% weight
Sample ID
HBA/ACPN
IV
loss T(° C.)
loss T(° C.)
Tg(° C.)
Tm(° C.)
Shao-02-126
80/20
NS b
414
428
—
325
Shao-02-133
75/25
NS
394
406
—
278
Shao-02-120
70/30
NS
425
438
~115
264
Shao-02-135
65/35
— a
400
414
—
249
Shao-02-199
65/35
—
401
415
—
260
Shao-02-203
63/37
—
390
412
—
270
Shao-02-121
60/40
NS
414
424
~120
275
Shao-02-201
60/40
—
393
412
—
267
Shao-02-198
55/45
—
412
427
—
261
Shao-02-207
55/45
—
388
408
—
267
Shao-02-125
50/50
NS
418
433
—
287
Shao-02-208
45/55
—
413
430
~115
293
a — means solubility was not attempted
b NS means not soluble
The Tg transitions were barely perceptible in the DSC curves, and the melting point peaks were broad and small. The enthalpy changes at the melting points were around 2.0–5.6 J/g, which is also very close to that of HNA/ACPN polymers.
Copolyesters from HBA/CAPN were also synthesized. Their compositions and properties were listed in Table 14. Solubility was very poor, therefore IV data was not obtained. This series of polymers produced some interesting DSC curves. Initially, the most prominent peak in the DSC curve appeared in the range of 175–210° C. The shape of the curve was similar to the shape of the DSC curves for the HBA/ACPN copolymers. It appears that hysteresis effects are also present in this series, and occasionally further complicated by relaxation effects near the Tg. As discussed previously, this behavior is a complex function of the previous thermal history on both heating and cooling conditions. When a faster heating rate (40° C./min) was used and the final temperature was increased to 460° C., a second endothermal peak appeared above 400° C., which is believed to be the melting point. The enthalpy change at the melting point was around 4.7–11.2 J/g, which is much higher than other series. Additionally, the Tg shape appeared similar to that described earlier for the HBA/ACPN series.
TABLE 14
Properties of HBA/CAPN copolyesters
Composition
5% weight
10% weight
Sample ID
HBA/CAPN
IV
loss T(° C.)
loss T(° C.)
Tg(° C.)?
Tm(° C.) a
Shao-02-250
80/20
NS
405
425
242
435
Shao-02-74
70/30
NS c
420
435
210
440
Shao-02-152
65/35
— b
426
430
189
430
Shao-02-251
65/35
—
415
433
191
431
Shao-02-156
55/45
—
409
424
163
417
Shao-02-75
50/50
NS
450
460
160
420
Shao-02-260
40/60
—
423
435
—
408
Shao-02-267
30/70
NS
420
434
—
413
Shao-02-270
20/80
a Temperature was taken from DSC test at a heating rate of 40 ° C./min.
b means solubility was not attempted.
c NS means not soluble
In summary, the polyesters from HBA/CAPN were quite similar to those from HBA/ACPN. One noticeable difference was the gradual shift in Tg with composition. The Tg shifts from 160° C. for the HBA/CAPN=50/50 composition to 242° C. for the 80/20 composition. A Tg shift of this magnitude has not been reported for wholly aromatic copolyesters. The melting points (420–440° C.) were much higher than those from HBA/ACPN.
Polyesters from B-B Monomer
The diacid monomer had very poor solubility and its melting point was much higher than other monomers (>350° C.). At 250–280° C., the monomer remained as a solid in the melted monomer mixture while the other monomers had already begun polymerization. As a result, only low molecular weight oligomers were produced.
Structure of Polyesters: Powder X-ray Patterns
The polyesters were ultrasonically treated to form a fine powder and x-ray spectra were taken at room temperature. Some of the polyesters showed very high degrees of crystallinity compared with VECTRA® (typical degree of crystallinity: 15–20%). Polyesters from HBA always gave higher degrees of crystallinity than those from HNA with similar composition, such as HBA/ACPN polyesters (40–45%,), HBA/CAPN polyesters (42–48%) and HBA/TA/DAPN polyesters (30–36%). When the HBA was replaced by HNA, the crystallinity decreased dramatically, such as HNA/CAPN (20–22%) and HNA/TA/DAPN (15–20%). Qualitatively, the differences can be observed since the more highly crystalline copolymers usually display several sharp peaks, while the less crystalline polymers display only a few peaks superimposed on an amorphous background. All of the data from x-ray was consistent with the previous DSC data and conclusions.
Liquid Crystal Behavior
The polyesters were studied under cross polarized microscope for their liquid crystal behavior and to confirm DSC results. Copolyesters from HNA/TA/DAPN have low melting points, thus were chosen for this investigation. The threaded texture did not disappear, even at 450° C. All of the polymers investigated in this thesis displayed similar textures and were consistent with classical nematic threaded textures.
In summary, different composition copolymers were synthesized successfully by copolymerization of TA, ABA or ANA with new phenylene-naphthalene monomers. The polymerization was carried out in bulk and at temperatures in the range of 250–330° C., and liquid crystalline polyesters with a relatively high molecular weight and thermal stablility were obtained. The composition greatly affected the properties of polymers.
Solubility of these polymers was very poor. Only a small number of polymers could be dissolved in PFP/PFB solution. The IV's were between 1.8 and 6.7 dL/g. Polyesters from all hydroxy-acid monomer systems showed poorer solubility and higher IV than those from systems incorporating diols.
The diacetoxy monomer, DAPN, was copolymerized with HBA or HNA and TA. The HBA copolymers showed much higher degrees of crystallinity and melting points, and lower solubilities than the HNA copolymers. The HNA/TA/DAPN polyesters were found to have even lower melting points than the commercial VECTRA® compositions.
The A-B (CAPN) and B-A (ACPN) monomers were copolymerized with HBA or HNA. These two series of polymers showed similar properties. HBA copolyesters showed unusually high Tg transitions which was confirmed by various TMA tests. HNA copolyesters showed much lower melting points than those of HBA copolyesters. The major difference between A-B and B-A series is the orientation of the ester bonds along the polymer chain. This also affected the polymer properties. For example, HBA/ACPN polymers showed a Tg at around 210° C., while the Tg's of HBA/CAPN polymers were 160–240° C. Their melting points and degrees of crystallinity were also quite different.
Some compositions showed degrees of crystallinity greater than 40%, which is very unusual for wholly aromatic LC polyesters. To our knowledge, these are some of the highest Tg's reported for wholly aromatic copolyesters to date.
In summary, the phenylene-naphthalene structure shows effects of lowering the melting points of polymers. Several series of polymers from HNA show even lower melting points than VECTRA® polymers. Also, some unexpected results were obtained, such as high Tg and high crystallinity of HBA copolymers.
Large Scale Synthesis of Copolyesters from A-A Monomer
As the HNA/TA/DAPN copolyesters provide the lowest melting points, and the monomer can be made from the least expensive starting materials, this composition was chosen for scale-up and fiber property evaluation. Monomers (HNA/TA/DAPN=60/20/20, 69.0 g of HNA, 16.6 g of TA and 32.0 g of DAPN) and catalyst KOAc (200˜300 ppm) were charged into a 3-necked round bottom flask equipped with a mechanical stirrer, and a nitrogen inlet and outlet. The system was degassed and purged with N 2 three times. While stirring and purging with N 2 , the temperature was increased to approximately 250° C. for 1.5–2 hours, 280° C. for 1 hr, 300° C. for 30 min. The vacuum was slowly introduced and lasted for 1–2 hr. When cooled to room temperature, the flask was broken and light brown hard solid was obtained.
Inherent viscosities (IV) of polymers were measured in a PFP/PFB (w/w=1.46/1) mixed solution at 30° C. with an Ubbelohde viscometer. The weighed polymer was dissolved in heated PFP first, and then PFB was added and mixed completely, with concentrations of approximately 0.2 g/dl. The solution was filtered with 1 μm filter before filling the viscometer.
Two batches of polyesters were synthesized in larger scale with the same composition (HNA/TA/DAPN=60/20/20). The first batch had a lower inherent viscosity (IV=3.0 dL/g), while the second batch experienced a longer time under vacuum at the final stage of the polymerization, and thus had a higher IV (3.9 dL/g).
Polyester Fibers
The granulated polymers were dried for several days. Before spinning, they were cold pressed into rods 4–7 cm in length and about 1 cm in diameter. Different spinning conditions were studied for both of the polymers. The results are listed in Table 15.
For Polyester I, the fiber broke occasionally when the Grid temperature was equal to or lower than 300° C. However, for grid temperature of 310° C. and 280° C. for pack temperature, stable fiber spinning was observed. The extrusion rate (through put) for most spinning trials was 0.3 cc/min. The fiber could be collected at 600–800 revolutions per minute (RPM) without substantial breaking of the fiber line. Therefore these optimized conditions were used for spinning polyester I.
TABLE 15
Spin Conditions for Polyester I*
Grid
Pack
Grid
Pack
RPM
Spin
Temperature
Temperature
Pressure
Pressure
(meters/
#
(° C.)
(° C.)
(psi)
(psi)
min)
1
300
270
185
70
800
2
280
260
385
70
600
3
280
250
447
700
800
4
280
250
985
380
600
6
310
280
221
280
600
7
310
280
268
810
800
*Polyester I: HNA/TA/DAPN = 60/20/20, IV = 3.0 dL/g
For polyester II, the first and second spinning trials were not successful. Some un-meltable impurities blocked the hole and continuous fiber was not obtained. The granulated polymer particles were put into tetrachloroethylene, which has a density of 1.6 g/cm 3 and stirred, and allowed to stand for 10 minutes. The majority of the polymer particles were floating on the top of the solvent, and some pieces of glass were at the bottom of the solvent. The separated polymer was dried again before spinning.
Mechanical tests of the fibers were conducted at Ticona. All tests were conducted at 50% room humidity (RH) and at 23° C. The average denier was calculated from the weight of 10 or 15 cm fils per sample. 10 tests were conducted for each sample and the reported numbers were their average values. The gauge length was 10 inches.
Mechanical test data for polymer I is listed in Table 16. Most of the modulus values are around 610–640 g/denier, which are approximately the same as VECTRA® polymers (˜600 g/denier). However, the break tenacity and break elongation were 3–5 g/denier and 0.7–0.9% respectively, somewhat lower than VECTRA® polymers (˜10 g/denier and 1–2%). I-1 and I-7 had lower modulus values, and the test data were slightly more scattered, indicating that some of the single fibers were weak. Many factors can influence the tenacity and elongation-to-break values including impurities, spinning conditions, polymer molecular weight, etc. Although it is impossible to study all of the parameters in a limited number of spinning trials, we suspect that the molecular weight (IV) of this batch of polymers may be the major factor related to these values.
TABLE 16
Mechanical properties of single fiber (as spun)
Spin
Modulus
Break Tenacity
Break
Number
Denier a
(g/denier)
(g/denier)
Elongation (%)
I-1
3.60
502.60
3.28
0.71
I-2
3.00
631.90
4.27
0.72
I-3
4.20
614.90
4.02
0.70
I-4
4.80
524.60
3.70
0.76
I-6
5.40
642.70
5.17
0.87
I-7
4.80
483.40
3.32
0.73
a Denier: gram per 9000 meters
The results indicate that this polymer can be spun into good fibers with a grid temperature of 310° C. and a pack temperature of 280° C. The mechanical modulus of these fibers is similar to or slight higher than the VECTRA® polymers. However, the tenacity modulus and break elongation were lower. | Liquid crystal polyester derived from phenylene-naphthalene monomers and one or more comonomers display an improved balance of properties, including low melt viscosity, fast cycle time in molding, very low mold shrinkage, high tensile and/or flexural strength, solvent resistance, excellent barrier properties, low water absorption, low thermal expansion coefficient, excellent thermostability, and/or low flammability. The phenylene-naphthalene monomers are
The one or more comonomers include 4-hydroxybenzoic acid, 2-hydroxy-6-naphthoic acid, terephthalic acid, isophthalic acid, and derivatives and combinations thereof. | 2 |
CLAIM OF PRIORITY
[0001] This application claims priority from U.S. provisional application 61/624,669, filed on Apr. 16, 2012, the contents of which are fully incorporated by reference.
FIELD OF THE INVENTION
[0002] The invention relates to a watercraft utility harness and more particularly relates to a watercraft utility harness that may be attached to boat guardrail cables to carry supplies such as fuel containers.
BACKGROUND OF THE INVENTION
[0003] Watercrafts, such as sailboats, fishing boats and yachts, are widely used for practical and entertaining purposes. It is desirable that the watercraft is capable of housing ample supplies such as fuel, drinkable water, and foodstuff to sustain a trip. However, due to limitations on board a watercraft, the ability to carry more supplies is in most occasions insufficient. In particular, having an extra supply of fuel, such as diesel, may enable the navigator to extend a trip and prepare for unanticipated conditions such as bad weather or accidents, thus improving the level of safety and enjoyment. Moreover, also due to the limited space on a watercraft, it is desirable to have a storing device that does not occupy too much space and that is easy to implement and access.
[0004] The current invention addresses such concerns by providing a watercraft utility harness that may be attached to the cables, especially the horizontal guardrail cables on a watercraft. Moreover, the utility harness introduced here may have broad usage aside from carrying supplies on a watercraft. With multiple advantageous designs in its attachment assembly and the materials used, the utility harness may be used in other environments as long as appropriate anchoring positions may be provided. In addition, the current invention provides the benefit of lightweight, portability, easy attachment, durability, and being inexpensive.
[0005] Some devices and systems have been developed for additional storage on a watercraft. These designs, however, show shortcomings in one aspect or another. For example, U.S. Pat. No. 4,756,455 discloses a utility saddlebag which has a top, sides, and ends and, of woven fabric attached together by seams of thread configured to cover the engine compartment enclosure of a jet-propelled watercraft. The saddlebag is held in place by the use of an elastic member sewn into a bead on the skirt or periphery of the device allowing it to be stretched over and held in place by tucking the ends under the edges of the housing. A number of pockets on the sides and on rear provide storage compartments, and strap assures closure on the sides. The invention provides storage for a watercraft, without any modification or alteration.
[0006] This design, however, requires the attachment of the saddlebag to the engine of the watercraft, making the usage of the saddlebag rather limited. Other various implements are also known in the art, but fail to address all of the problems solved by the invention described herein. The preferred embodiment of this invention is illustrated in the accompanying drawings and will be described in more detail herein below.
SUMMARY OF THE INVENTION
[0007] The present invention discloses a watercraft utility harness having a hanging piece and a utility pocket. The hanging piece has an upper edge, a front side and a back side. The utility pocket has a top opening, a front piece, a back piece, and side pieces. The back piece of the utility pocket is attached to the front side of the hanging piece. There are one or more front straps attached to the front side of the hanging piece and releasably connect to the front piece of the utility pocket. There is a back top flap having a top edge and a lower portion, the top edge being permanently attached to the back side of the hanging piece and the lower portion releasably attached to the back side of the hanging piece. Moreover, there are one or more back straps each having an upper point and a lower part, wherein the upper point is permanently attached to the back side of the hanging piece and the lower part of the first back strap is releasably connected to the back side of the hanging piece. When the front strap is connected to the front piece of the utility pocket, it partially covers the top opening of the utility pocket, preventing the items stored in the utility pocket from falling out.
[0008] The watercraft utility harness may be attached to the horizontal guardrail cables on a watercraft. In almost all the watercrafts, guardrail cables are used to serve as a fence at the edge of the watercraft and prevent accidental falling of persons or items into the water. The guardrail cables are attached to the guardrails and form horizontal barriers. The structure of the guardrails is generally robust and the guardrail cables are strong and well-positioned. These are the ideal places to hang extra supplies, especially when the proper devices like the utility harness introduced in the current invention are available.
[0009] In most occasions, there are two guardrails cables attached to the guardrails and these two cables are aligned horizontally parallel to the floor of the watercraft, with one cable positioned higher than the other. The back top flap of the hanging piece of the utility harness may embrace the upper guardrail cable when the lower portion of the back top flap is connected to the back of the hanging piece. Similarly, the back straps may embrace the lower guardrail cable when the lower parts of the back straps are connected to the back of the hanging piece. The back flap and back straps provide the support to hang the utility harness or at least anchor the utility harness by preventing it from falling down or tilting over. The two-guardrail-cable design is particularly suitable for the latter purpose. It should be noted that with proper selection of materials that make up the hanging piece and proper design for the thickness and robustness of the back flap and back straps, it is possible to hang the utility harness on a single guardrail cable. However, it is preferred to utilize both upper and lower guardrail cables to hang the utility harness.
[0010] The utility harness may be used to store anything. It is particular useful for the carrying and storing of watercraft supplies such as fuel, drinkable water, food stuffs, and safety devices. The specific design of the hanging piece and utility pocket may vary according to the type of watercraft and the items and substances that will be carried. For example, the utility harness may be designed specifically to carry fuel containers with a fixed size. The extra fuel may enable the user of the watercraft to prolong a trip and deal with unanticipated events such as bad weather and accidents.
[0011] The utility pocket may be used as a unitary structure, or it may be divided by separators into sub-pockets that may be individually useful for storing the same or different items. For example, two separators may be disposed in the utility pocket to divide it into three sub-pockets, with each sub-pocket being sized to carry a fuel container. The fuel container may have a handle and the front strap may be threaded under the handle before being attached to the front piece of the utility pocket, ensuring that the fuel container is firmly placed in each sub-pocket.
[0012] The hanging piece and utility pocket may be made from various kinds of materials. Preferably, the hanging piece and the utility pocket are made from lightweight materials that are robust and durable. Such a design not only improves the portability of the utility harness and makes the implementation particularly easy, but also ensures that the utility harness is safe, reliable, and may be used for a long period of time. In addition, it is preferable that the utility harness is made from waterproof and porous materials, preventing the accumulation of water in the utility pocket and preventing damping of the utility harness.
[0013] In general, the present invention succeeds in conferring the following, and others not mentioned, desirable and useful benefits and objectives.
[0014] It is an object of the present invention to provide a watercraft utility harness that is safe and easy to use.
[0015] It is another object of the present invention to provide a watercraft utility harness having multiple sub-pockets or compartments for storage.
[0016] It is another object of the present invention to provide a watercraft utility harness that may be easily attached to cables.
[0017] It is another object of the present invention to provide an embodiment of a watercraft utility harness that may be easily attached to the guardrail cables on a watercraft.
[0018] Yet another object of the present invention is to provide a watercraft utility harness that may be used to house one or more fuel containers.
[0019] Still another object of the present invention is to provide a watercraft utility harness that does not cause water accumulation.
[0020] It is another object of the present invention to provide a watercraft utility harness that is robust and durable.
[0021] Still another object of the present invention is to provide a watercraft utility harness that is inexpensive.
[0022] Still another object of the present invention is to provide watercraft utility harness having different sizes and dimensions to fit the needs for different watercrafts, different storing requirements and different conditions.
[0023] It is a further object of the invention to provide a watercraft utility harness that is easy to manufacture.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] FIG. 1 shows a top back perspective view of a preferred embodiment of the watercraft utility harness when it is hung on the guardrail cables.
[0025] FIG. 2 shows a top front perspective view of a preferred embodiment of the watercraft utility harness when it is hung on the guardrail cables.
[0026] FIG. 3 shows a top front perspective view of a sub-pocket when a fuel container is stored therein.
[0027] FIG. 4 shows a top front perspective view of the details of a snap fastener assembly.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0028] The preferred embodiments of the present invention will now be described with reference to the drawings. Identical elements in the various figures are identified, as far as possible, with the same reference numerals.
[0029] Reference will now be made in detail to embodiments of the present invention. Such embodiments are provided by way of explanation of the present invention, which is not intended to be limited thereto. In fact, those of ordinary skill in the art may appreciate upon reading the present specification and viewing the present drawings that various modifications and variations can be made thereto without deviating from the innovative concepts of the invention.
[0030] FIG. 1 shows a top back perspective view of a preferred embodiment of the watercraft utility harness when it is hung on the guardrail cables. Shown in FIG. 1 is the watercraft utility harness 1 comprising a hanging piece 10 and a utility pocket 20 ; the hanging piece 10 has a back side 18 and an upper edge 21 ; the utility pocket 20 has a back piece 25 and side pieces 22 . Also shown in FIG. 1 are the back top flap 90 having a top edge 93 and a lower portion 96 , the top edge 93 of the back top flap 90 being aligned with and permanently attached to the upper edge 21 of the hanging piece 10 and the lower portion 96 of the back top flap 90 being releasably attached to the back side 18 of the hanging piece 10 with a plurality of snap fastener assemblies 70 . In addition, FIG. 1 also shows a first back strap 100 , a second back strap 110 , and a third back strap 120 , each having an upper point 121 and a lower part 122 , the upper points 121 are permanently attached to the back side 18 of the hanging piece 10 and the lower parts 122 are releasably connected to the back side 18 of the hanging piece 10 with snap fastener assemblies 70 . For clarity purposes, not all snap fastener assemblies 70 are marked.
[0031] “Permanent attachment,” as used herein, refers to the type of attachments that may not be broken without damaging the integrity of the basic structures of the connecting mechanism or the parts being connected. On the other hand, a “releasable attachment” refers to an attachment that may be broken without the destruction of the connecting mechanism or the connected parts.
[0032] In FIG. 1 , the watercraft utility harness 1 is hung on guardrail cables comprising an upper guardrail cable 150 and a lower guardrail cable 160 . When the lower portion 96 of the back top flap 90 is connected to the back side 18 of the hanging piece 10 , the back top flap 90 and the hanging piece 10 embrace the upper guardrail cable 150 . Similarly, when the lower parts 122 of the back straps are releasably connected to the back side 18 of the hanging piece 10 , the back straps and the hanging piece 10 embrace the lower guardrail cable 160 . These structures provide the necessary forces that hang the watercraft utility harness 1 on the guardrail cables. At the very least, even if the watercraft utility harness 1 is not fully suspended, the hanging piece 10 , the back top flap 90 , and back straps anchor the watercraft utility harness 1 and prevent it from fall down or tilting over.
[0033] In addition to the back top flap 90 and the back straps, there are anchoring holes 125 on the hanging piece 10 , wherein attachment cords 180 may be used to thread through the anchoring holes 125 to provide more stability to the watercraft utility harness 1 . Preferably, the anchoring holes 125 are located on the corners of the hanging piece 10 , allowing easy access by the attachment cords 180 , which may be connected to the guardrails or other stable structures on the watercraft.
[0034] FIG. 2 shows a top front perspective view of a preferred embodiment of the watercraft utility harness when it is hung on the guardrail cables. Shown in FIG. 2 is the watercraft utility harness 1 having a hanging piece 10 and a utility pocket 20 , wherein the hanging piece 10 has an upper edge 21 and a front side 15 and the utility pocket 20 has a top opening 24 , a front piece 27 and side pieces 22 . Also shown in FIG. 2 are a first front strap 55 , a second front strap 60 , a third front strap 65 , with one end of the front straps being permanently attached to the front side 15 of the hanging piece 10 (not shown in FIG. 2 ) and the other end of the front straps being releasably attached to the front piece 27 of the utility pocket 20 with snap fastener assemblies 70 . For clarity purposes, not all snap fastener assemblies 70 are marked. Also shown in FIG. 2 are the upper guardrail cable 150 and the lower guardrail cable 160 being used to hang watercraft utility harness 1 , the anchoring holes 125 on the hanging piece 10 and the attachment cords 180 threaded through the anchoring holes 125 . The basic usages of such structures are discussed above in FIG. 1 .
[0035] In FIG. 2 , the utility pocket 20 is divided by a first separator 35 and a second separator 45 into three sub-pockets. The first separator 35 and the second separator 45 are disposed in the utility pocket 20 and are generally parallel to the side pieces 22 , dividing the utility pocket 20 into a first sub-pocket 30 , a second sub-pocket 40 , and a third sub-pocket 50 . Three fuel containers 200 are kept in the three sub-pockets. Each fuel container 200 has a handle 210 and the front straps thread under the handles 210 to connect to the front piece 27 , ensuring that the fuel containers are properly secured in the utility pocket 20 .
[0036] It should be noted that the utility pocket 20 does not necessarily have to be separated, nor is it paramount that the utility pocket 20 be divided into three sub-pockets. The utility pocket 20 may be a single pocket or it may be divided into two or more sub-pockets having similar or different sizes and locations. The compartmentalization of the utility pocket 20 may be adjusted according to the size and weight of the supplies to be carried, the durability of the guardrails and cables, and the actual necessities of the user.
[0037] The key function of the front straps is to prevent whatever that is stored in the utility pocket to fall out. The possible tumultuous environment a watercraft may encounter, such as storms and heavy rain, requires that some enclosing mechanism be employed to secure the storage in the utility pocket. However, the design shown in FIG. 2 is not the only possibility. The precise format of the enclosing mechanism may be altered according to the specific needs of the user and the likelihood of falling out. For example, a cover completely enclosing the top opening 24 of the utility pocket 10 may be used to ensure full closure.
[0038] In terms of materials, the hanging piece 10 and the utility pocket 20 may be made from the same or different materials. More particularly, the various components of the watercraft utility harness may be made from the same or different materials. The materials that may be used include but are not limited to: metal, rubber, and plastic such as, but not limited to, polyethylene (PE), high-density polyethylene, polyvinyl chloride (PVC), polyvinylidene chloride (PVDC), low-density polyethylene (LDPE), polypropylene (PP), polystyrene (PS), polyesters, vinyl, (HIPS) and polycarbonate (PC), mesh fabric, or paperboard coated with a suitable waterproof coating such as, but not limited to, polyethylene, or some combination thereof. The material is preferred to be safe, strong, flexible, and waterproof. Moreover, it would be desirable that the material is inexpensive and easy to manufacture.
[0039] It is preferred that the utility pocket 20 is made porous so that water does not accumulate in the utility pocket 20 . Due to waves, splashes, and rain, it is very likely that water may get access to the utility pocket 20 when the utility harness is installed on a watercraft. However, the accumulation of water may cause deterioration of the substances stored in the utility pocket 20 . Moreover, the accumulated water adds to the weight that needs to be sustained by the hanging piece, making it more likely to collapse. Therefore, it is preferred that the utility pocket 10 is made from porous material. The preferred material for the hanging piece and utility pocket is Phifertex® mesh fabrics.
[0040] The dimension of the utility harness may be adjusted according to the supplies being carried, the necessities of the user, and the actual conditions likely to be encountered. The variations for the dimensions of the components of the utility harness are almost limitless. As shown FIG. 1 and FIG. 2 , this particular preferred embodiment is designed to carry fuel containers. The width, height, and depth of the sub-pocket here may range from 1 to 100 inches (2.5-2500 cm), with the dimension of approximately 13×16×8 inches (33×40×20 cm). As shown in FIG. 2 , the fuel containers 200 have container handles 210 that are exposed. The front straps may be threaded under the container handles 210 to ensure that the containers are properly secured.
[0041] As to the size of the hanging piece 10 and the utility pocket 20 as a whole, there are also many variations. It is preferred that the width of the hanging piece 10 is similar to, but not smaller than the width of the utility pocket 20 . In the preferred embodiment, the width of the hanging piece 10 and the utility pocket 20 may range from 5-100 inches (12.5 to 1250 cm), with the preferred width to be approximately 50 inches (127 cm). The space between the back strap and the back flap is another essential dimension of the utility harness. In particular, it is preferred that the distance between the top edge 93 of the back flap 90 and the first point 121 of the back straps is similar to the distance between the top guardrail cable 150 and the bottom guardrail cable 160 . With such a design, both the back straps and back flap structures are put to use when the hanging piece is properly attached to the guardrail cables.
[0042] It should also be noted that although the preferred embodiment is designed to hang from guardrails cables on a watercraft, it is still possible that the utility harness introduced by the current invention may be hung on other structures on a watercraft. Moreover, it is also possible that the current invention be used in other settings not a watercraft. As long as the key structures are the same, the use of the utility harness may vary according to the user's needs.
[0043] FIG. 3 shows a top front perspective view of a sub-pocket when a fuel container is stored therein. Shown in FIG. 3 are the second sub-pocket 40 , the first separator 35 , the second front strap 60 , the front piece 27 of the utility pocket 20 , the snap fastener assembly 70 , and the fuel container 200 having a handle 210 , the fuel container 200 being stored in the second sub-pocket 40 . FIG. 3 provides a more detailed depiction of how the fuel container 200 is being secured in the utility pocket 20 .
[0044] FIG. 4 shows a top front perspective view of the details of a snap fastener assembly 70 . The snap fastener assembly 70 shown here is just one of the possible ways to releasably attach the front straps to the front piece 27 of the utility pocket 20 . It is also one of the many possible options to releasably attach the lower part 93 of the back flap 90 to the back side 18 of the hanging piece 10 . Similarly, it is one of the options to releasably attach the second point 122 of the front straps to the front piece 27 of the utility pocket 20 . Other possible options include but are not limited to: cross snaps, rivets, magnets, and hook-and-loop structures. Here in FIG. 4 the example demonstrates the snap fastener assembly 70 used to attach the second front strap 60 to the front piece 27 .
[0045] As shown in FIG. 4 , the snap fastener assembly 70 comprises an oval ring 85 encircling an oval opening 80 , the oval ring 85 and the oval opening 80 are located on the second front strap 60 (not shown in FIG. 4 ). The snap fastener assembly 70 further comprises a fastening fin 75 rotatably disposed on a base platform 72 , the base platform 72 being secured to the front piece 27 (not shown in FIG. 4 ). The length of the fastening fin 75 is shorter than the long diameter of the oval opening 80 but longer than the shorter diameter of the oval opening 80 . Thus, the fastening fin 75 may be inserted through the oval opening 80 when the fastening fin 75 is aligned with the longer diameter of the oval opening. After insertion, the fastening fin 75 may be rotated to secure the fastening fin 75 on the oval ring 85 .
[0046] Although this invention has been described with a certain degree of particularity, it is to be understood that the present disclosure has been made only by way of illustration and that numerous changes in the details of construction and arrangement of parts may be resorted to without departing from the spirit and the scope of the invention. | A watercraft utility harness having a hanging piece and a utility pocket attached to the hanging piece. Separators may be disposed in the utility pocket to divide the utility pocket into sub-pockets that may house necessary items. There are attachment straps and flaps on the back of the hanging piece, allowing the watercraft utility harness to be hung on watercraft guardrail cords. There are front straps on the front side of the utility harness, preventing the items stored in the utility pocket from falling out. The utility harness is particularly suitable to store fuel containers and provide backup fuel supply for the watercraft. The utility pockets and sub-pockets may be sized specifically for this purpose. | 1 |
CROSS REFERENCE TO RELATED PATENT APPLICATION
The present patent application claims the right of priority under 35 U.S.C. §119 (a)-(d) of German Patent Application No. 103 49 504.5, filed Oct. 23, 2003.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention is directed to a process for preparing isocyanates in the gas phase and in particular to improved mixing of the reactants used in such a process.
2. Description of the Prior Art
EP-A 0 289 840 describes a process for preparing (cyclo)aliphatic diisocyanates by phosgenation of the corresponding, gaseous (cyclo)aliphatic diamines at from 200° C. to 600° C. Phosgene is introduced in a stoichiometric excess. The superheated streams of, firstly, gaseous (cyclo)aliphatic diamine or (cyclo)aliphatic diamine/inert gas mixture and, secondly, phosgene are fed continuously into a cylindrical reaction chamber, mixed with one another there and reacted. The exothermic phosgenation reaction is carried out with turbulent flow being maintained.
Gaseous starting materials are frequently reacted in tube reactors. In the case of the jet mixer principle (Chemie-Ing.-Techn. 44 (1972) p. 1055, FIG. 10), two feed streams A and B are fed into the reactor, with feed stream A being introduced via a central nozzle and feed stream B being introduced via an annular space between the central nozzle and the wall of the tube reactor. The flow velocity of the feed stream A is high compared to the flow velocity of the feed stream B. As a result, the mixing of the reactants and consequently the reaction between them occur in the tube reactor. This way of carrying out the reaction has achieved industrial importance in the preparation of aromatic diisocyanates by phosgenation of aromatic diamines in the gase phase (e.g. EP-A-0 570 799).
The known processes require very long reactors since mixing occurs slowly without additional measures.
A consequence of the slow mixing of the reactants is the formation of polymeric by-products which lead to caking and even blockages in the reactor and thus shorten the operating period of the reactors. In addition, the greater lengths of the reactors lead to increased capital costs.
It is therefore an object of the invention to find a process for preparing (cyclo)aliphatic and aromatic diisocyanates by phosgenation of corresponding (cyclo)aliphatic and aromatic diamines in the gas phase at high temperatures, in which mixing of the reactants occurs significantly more quickly than in the processes known hitherto.
SUMMARY OF THE INVENTION
The present invention relates to a process for preparing isocyanates in the gas phase, in which the mixing of the reactants is significantly improved by means of improved reaction conditions in tube reactors using hydrodynamic measures such as increasing the turbulence. As a consequence, the necessary residence time of the reactants in the reactor and thus the length of reactor needed are shortened and the formation of polymeric by-products which lead to caking in the reactor and a shortening of the operating period of the reactors is avoided.
Thus, the present invention is directed to a process for preparing diisocyanates and triisocyanates of the general formula (I)
R(NCO) n (I)
where
R is a (cyclo)aliphatic or aromatic hydrocarbon radical having up to 15 carbon atoms, with the proviso that at least two carbon atoms are present between two NCO groups and n is 2 or 3,
The inventive process includes phosgenating diamines and/or triamines of the general formula (II) in the gas phase
R(NH 2 ) n (II)
where R is a (cyclo)aliphatic or aromatic hydrocarbon radical having up to 15 carbon atoms, with the proviso that at least two carbon atoms are present between two amino groups and n is 2 or 3, where the phosgenating is carried out in a tube reactor having a central nozzle and an annular space between the central nozzle and a wall of the tube reactor, wherein turbulence is generated in the central nozzle and in which a feed stream containing the diamines and/or triamines is fed into the tube reactor via the central nozzle and a phosgene-containing feed stream is fed into the tube reactor via the annular space.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a partial elevation view of a tube reactor according to the invention;
FIG. 2A shows a side elevation view of an oblique plate as a turbulence generator for the tube reactor in FIG. 1 ;
FIG. 2B shows a plan view of an oblique plate as a turbulence generator for the tube reactor in FIG. 1 ; and
FIG. 3 shows a helical element that can be used as a turbulence generator in the tube reactor of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Other than in the operating examples, or where otherwise indicated, all numbers or expressions referring to quantities of ingredients, reaction conditions, etc. used in the specification and claims are to be understood as modified in all instances by the term “about.”
It has now surprisingly been found that increasing the turbulence of the feed stream in the central nozzle has a positive influence on the mixing of the reactants and thus on the gas-phase reaction as a whole. As a consequence of the better mixing, the tendency for by-products to be formed decreases and the necessary residence time and thus reactor length drop significantly. Thus, the disadvantages of the processes of the prior art can be significantly reduced when the feed streams are subjected to the novel measures described in more detail below.
The invention provides a process for preparing diisocyanates and triisocyanates of the general formula (I)
R(NCO) n (I)
where
R is a (cyclo)aliphatic or aromatic hydrocarbon radical having up to 15 carbon atoms, preferably from 4 to 13 carbon atoms, with the proviso that at least two carbon atoms are present between two NCO groups and n is 2 or 3,
by phosgenation of the corresponding diamines and/or triamines of the general formula (II) in the gas phase
R(NH 2 ) n (II)
where
R is a (cyclo)aliphatic or aromatic hydrocarbon radical having up to 15, preferably from 4 to 13, carbon atoms, with the proviso that at least two carbon atoms are present between two amino groups and n is 2 or 3,
characterized in that the phosgenation is carried out in a tube reactor having a central nozzle and an annular space between the central nozzle and the wall of the tube reactor, with the central nozzle being centred in the tube reactor and the central nozzle being connected to an inlet for one of the feed streams and the inlet for a second feed stream being located in the annular space and with turbulence being generated in the central nozzle,
in which the feed stream containing the diamines and/or triamines is fed into the tube reactor via the central nozzle and the phosgene-containing feed stream is fed into the tube reactor via the annular space. The degree of turbulence of the stream flowing through the central nozzle is preferably increased by means of internal elements.
In an alternative embodiment of the process of the invention, the feed stream containing the diamines and/or triamines and the phosgene-containing feed stream are interchanged so that the feed stream containing the diamines and/or triamines is fed into the tube reactor via the annular space and the phosgene-containing feed stream is fed into the tube reactor via the central nozzle.
Preference is given to using one or more round or annular plates installed obliquely in the stream or a helix as turbulence-increasing internal elements in the central nozzle.
The task of the oblique plate or the combination of a plurality of oblique plates is to increase the degree of turbulence in the central nozzle.
The task of the helix is to increase the degree of turbulence in the stream in the central nozzle and to twist the stream in order to utilize centrifugal effects to aid mixing of inner and outer streams.
The process of the invention makes it possible to shorten the mixing distance of feed streams fed in via the annular space and via the central nozzle by at least 50% compared to the comparative value without turbulence-generating internals.
In the process of the invention, diisocyanates and/or triisocyanates are prepared from the corresponding diamines and/or triamines.
Preference is given to preparing diisocyanates by phosgenation of the corresponding diamines in the process of the invention.
As triisocyanate of the formula (I), 1,8-diisocyanato-4-(isocyanatomethyl)octane, also known as triisocyanatononane (TIN), is preferably prepared in the process of the invention.
Typical examples of suitable aliphatic diamines are mentioned in, for example, EP-A 0 289 840, and typical examples of suitable aliphatic triamines are mentioned in, for example, EP-A 749 958. These diamines are suitable for preparing the corresponding diisocyanates or triisocyanates by the process of the invention.
Preference is given to isophoronediamine (IPDA), hexamethylenediamine (HDA) and bis(p-aminocyclohexyl)methane.
Typical examples of suitable aromatic diamines are the pure isomers or the isomer mixtures of diaminobenzene, diaminotoluene, diaminodimethylbenzene, diaminonaphthalene and diaminodiphenylmethane; preference is given to 2,4-/2,6-toluenediamine mixtures having isomer ratios of 80/20 and 65/35 or the pure 2,4-toluenediamine isomer.
As triamine, preference is given to using 1,8-diamino-4-(aminomethyl)octane, also known as triaminononane.
The starting amines of the formula (II) are fed into the reactor in gaseous form and are, if appropriate, vaporized and preferably heated to from 200° C. to 600° C., particularly preferably from 250° C. to 450° C., before carrying out the process of the invention and are fed, if appropriate after dilution with an inert gas such as N 2 , Ne, He, Ar or with the vapour of an inert solvent, into the reactor. The phosgene is fed into the tube reactor in a stoichiometric excess and at from 200° C. to 600° C. When using aliphatic diamines, the molar excess of phosgene based on one amino group is preferably from 25% to 250%,
and when using aliphatic triamines is preferably from 50% to 350%. When aromatic diamines are used, the molar excess of phosgene based on an amino group is preferably from 150% to 300%.
In the following, the invention is illustrated by way of example with the aid of FIG. 1 . The feed stream A (diamine and/or triamine) flows via the inlet 1 and the central nozzle 5 into the tube reactor 6 .
The central nozzle 5 is held in position by the lid 2 and the holder 4 and is centred on the axis of rotation of the tube reactor 6 . One or more turbulence-generating elements 7 are located in the central nozzle.
The feed stream B (phosgene) flows through the inlet 8 into the annular space 3 of the tube reactor 6 .
FIGS. 2A and 2B show a preferred oblique plate as turbulence generator 7 .
FIG. 3 shows a preferred helical element 8 as turbulence generator 7 .
EXAMPLE
Starting materials A and B are fed, in each case as a gas, into a model tube reactor as shown in FIG. 1 (length: 2000 mm, internal diameter of the outer tube: 172 mm, internal diameter of the inner tube: 54 mm), with the gas of the inner stream (starting material A) being seeded by addition of aerosols.
The experiment is firstly carried out according to the invention using a helix as shown in FIG. 3 as turbulence-generating element in the central nozzle; the length of the helix was 135 mm, its diameter was 54 mm, and the twist was 360°.
Secondly, the experiment is carried out without turbulence-generating internals in the central nozzle for comparison.
Mixing of inner and outer streams downstream of the mouth of the central nozzle can then be assessed visually on the basis of the radial distribution of the aerosols of the inner stream. Complete mixing of inner and outer streams is regarded as having been achieved when the aerosols from the inner stream have reached the wall of the outer tube. The axial length of the path in the tube reactor from the mouth of the central nozzle to this point will hereinafter be referred to as the mixing distance.
In the experiment carried out as comparative example, the mixing distance was 1200 mm. In the experiment carried out according to the invention using the helix as turbulence-generating internal element, the mixing distance was only 500 mm. The mixing distance in the process of the invention is thus only 42% of the original distance.
Although the invention has been described in detail in the foregoing for the purpose of illustration, it is to be understood that such detail is solely for that purpose and that variations can be made therein by those skilled in the art without departing from the spirit and scope of the invention except as it may be limited by the claims. | A process for preparing isocyanates in the gas phase, in which the mixing of the reactants and thus the reaction conditions are significantly improved by means of hydrodynamic measures such as increasing the turbulence of the feed stream in the central nozzle. As a consequence, the necessary residence time in the reactor and thus the length of the reactor are reduced and the formation of polymeric by-products which lead to caking in the reactor and a shortening of the operating period of the reactors is avoided. | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to dispensing units in general, and, in particular, to manually operated devices for dispensing elongated articles from a reservoir of such articles.
2. Description of the Prior Art
The prior art is generally cognizant of receptacles for dispensing elongated articles in which a tab or arm is depressed by a user so as to dispense a single elongated article, such as a drinking straw, match, or cigarette. The prior art is also generally cognizant of such dispensing units in which a pivotably mounted member carries a single one of the articles from inside of the unit to outside thereof. One example of such a unit is shown in U.S. Pat. No. 1,008,867. Other examples of apparatus design for dispensing such elongated articles are shown in U.S. Pat. Nos. 592,105, 1,229,982, 1,676,109, 1,678,355, and 1,773,329. While some of the prior art devices have suitable means for preventing jamming of the articles at the exterior of the storage portion of the unit, it has been a problem with some of the prior art devices in that the articles may, on occasion, jam inside of the storage area for the articles, so that the jam is not accessible to the user of the unit.
SUMMARY OF THE INVENTION
The present invention is summarized in that a dispensing unit for a plurality of elongated articles having a fixed cross-sectional diameter includes a rectangular storage bin for receiving the articles therein having at least one dispensing port formed therein, a bottom bracket installed in the storage bin so as to bias the articles to roll toward the dispensing port, a dispensing member mounted in the storage bin adjacent the dispensing port therein so as to be pivotable between a rest and a dispensing position, a support shelf on the dispensing member for supporting the objects thereon, a carrying portion of the dispensing recessed downward from the support shelf and extending out of the dispensing port, a pinch bar on the dispensing member extending from the support shelf and spaced over the carrying portion, and a sorting tab mounted on the interior of the storage bin above the dispensing port and located so that the distance between the sorting tab and pinch bar in its rest position is greater than the diameter of the articles and less than two such diameters.
It is an object of the present invention to construct a dispensing unit for elongated articles in which the possibility of the objects jamming within the unit is reduced to the greatest extent practicable.
It is another object of the present invention to provide such a unit including means therein to periodically jostle the articles within the storage bin so that the proper alignment of the articles for sequential dispensing is maintained at all times.
It is yet another object of the present invention to provide such a dispensing unit that is both efficient in its operation and economical to manufacture.
Yet other objects, advantages, and features of the present invention will become apparent from the following specification when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a dispensing unit constructed in accordance with the present invention.
FIG. 2 is a cross-sectional view taken along the line 2--2 in FIG. 1.
FIG. 3 is a cross-sectional view taken along the line 3--3 in FIG. 1.
FIG. 4 is a rear perspective view of an alternative embodiment of a dispensing member and sorting tab construction suitable for use in the dispensing unit of FIG. 1.
FIG. 5 is a cross-sectional view of an alternative embodiment of a dispensing unit constructed in accordance with the present invention.
FIG. 6 is a cross-sectional view of the dispensing unit of FIG. 5 with the dispensing member being depressed to its dispensing position.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Shown in FIG. 1 is a dispensing unit for dispensing elongated articles, generally indicated at 10, constructed in accordance with the present invention. The dispensing unit 10 includes a generally rectangular storage bin 12 which has a pair of dispensing ports 14 formed in it along the lower edges of each of its longer sides. The storage bin 12 has an open top onto which a removable top closure 16 is fitted, with the removable top closure 16 being preferably formed of a transparent material. The top closure 16 is fully removable from the top of the storage bin 12.
As can be seen in the cross-sectional views of the dispensing unit 10 as shown in FIGS. 2 and 3, the organization of the interior of the storage bin 12 is generally symmetrical about a center axis. Along that center axis a center bracket 18 is formed of a generally U-shape, with the center bracket 18 extending the complete longitudinal distance of the storage bin 12 along the center line thereof. The center bracket 18 is located a substantial distance upward from the bottom of the storage bin 12. Attached to the center bracket 18 are a pair of bottom brackets 20 which generally taper downward in a slanted direction from the center bracket 18 toward the dispensing ports 14. At their interior ends the bottom brackets 20 are each fixedly joined to the center bracket 18. At their other ends the bottom brackets 20 are each bent vertically downward until they contact the bottom of the storage bin 12, after which they are bent again so as to line on the interior of the bottom of the storage bin 20 to which they are there attached. A pair of forwardly extending hinge tabs 22 are formed extending from the longitudinal ends of the vertically extending portions of each of the bottom brackets 20. Extending between the hinge tabs 22 on each side of the interior of the storage bin 12 and extending out of the dispensing ports 14 are a pair of respective dispensing members, indicated at 24. The dispensing members 24 each has a hinge tab 26 extending downwardly in a vertical plane from each of the extreme longitudinal ends thereof so as to be received fixedly and rotatably within the hinge tabs 22 of the bottom brackets 20, as is better seen in FIG. 3. The dispensing members 24 each includes a longitudinally extending thin, planar, support shelf 28 extending between the hinge tabs 26. A pair of spring arms 30 are formed extending downward at right angles relative to the support shelves 28 and have openings formed near the bottom ends thereof. A leaf spring 32 is provided extending from the opening in each of the two spring arms 30 on each dispensing member 24 to correspondingly located openings in the center bracket 18 and openings are provided in the bottom brackets 20 to allow the springs 32 to extend therethrough when flexed as shown in FIGS. 2 and 3. Toward its front surface, the dispensing members 24 are each provided with a pair of outwardly extending dispensing tabs 34 extending through the respective dispensing ports 14. The dispensing tabs 34 each include a recessed carrying portion 36 which is recessed somewhat downwardly from the plane of the support shelf 28 and which extends outwardly through the dispensing port 14 beyond the exterior lateral wall of the storage bin 12. A small retaining ridge 38 extends upwardly from the carrying portion 36 exterior of the outside wall of the storage bin 12. A pressing pad 40 is provided at the extreme end of the dispensing tabs 34, upraised slightly from the carrying portions 36, and is arranged at an angle and provided with a size convenient for pressing by the finger of a user. On the interior lateral side walls of the storage bin 12, above each of the dispensing ports 14, a pair of sorting tabs 42 are fastened to the interior of these walls. The sorting tabs 42 are each fixedly attached to the interior wall of the storage bin 12 and then depend downwardly and outwardly therefrom and have their lower ends bent at a right angle back toward that wall at a fixed distance above the support shelf 28. The distance at which the sorting tabs 42 as separated from the support shelf 28, with the dispensing member 24 positioned in its rest position as shown in the left hand side of each of FIGS. 2 and 3, is selected so as to be greater than the diameter of the articles to be dispensed, but less than, the length of two diameters of such articles. Underneath and aligned with each of the sorting tabs 42 above each of the support shelves 28, is a pinch bar 44 which is formed as a small extension of the support shelf 28 positioned spaced above the carrying portion 36. The length of the pinch bars 44 is selected so as to terminate a distance from the interior wall of the storage bin 12 which is slightly greater than the diameter of the articles to be dispensed, but less than two such diameters, when the dispensing member 24 is in its rest position, as shown on the left hand side of FIGS. 2 and 3 dispensing unit 10.
As can be seen in FIGS. 2 and 3 a pair of the dispensing members 24 are provided in each dispensing unit 10 on opposite side of the storage bin corresponding with the location of the dispensing ports 14. The dispensing members 24 are shown in each of FIGS. 2 and 3 in both of their two operating positions. The left hand dispensing member 24 in each of FIGS. 2 and 3 is shown in its rest position, and the right hand dispensing member 24 in each of FIGS. 2 and 3 shown in its dispensing position. As can be seen from these two figures, the limit of level of the pivoting dispensing members 24 is limited by the perimeter of the dispensing ports 14 inasmuch as the carrying portions 36 of the dispensing members 24 contact the opposite edges of the storage bin 12 forming upper and lower edge of the dispensing port 14 in its rest and dispensing positions.
In its operation the dispensing unit 10 allows elongated articles to be dispensing one at a time from each of the dispensing ports 14. The articles to be dispensed, as illustrated in the embodiment disclosed herein are drinking straws, but it is contemplated that any similar elongated articles may be dispensed from the dispensing unit 10. As can be seen in the left hand side of each of the FIGS. 2 and 3, the straws awaiting to be dispensed are received on the support shelf 28. A single straw, which will be the next straw to be dispensed, is received on the carrying portion 36 beneath the pinch bar 44 and just inside of the side wall of the storage bin 12. The straw which is next in turn for being dispensed is received just above the pinch bar 44, resting on the straw beneath, and directly beneath the sorting tab 42. To operate the dispensing unit 10 the user simply presses on the pressing pad 44 of either of the dispensing tabs 34 on the respective dispensing member 24. This pressure pivots the dispensing member 24 from its rest position, as shown in the left hand side of FIGS. 2 and 3, to its dispensing position, as shown on the right hand side of FIGS. 2 and 3. The pivoting of the dispensing member 24 to its dispensing position causes the straw that was already on the carrying portion 36 to be freed from the inside of the storage bin 12, so that it rolls down the carrying portion 36 and over the retaining rib 38. A straw is shown in this position in the right hand side of each of FIGS. 2 and 3. The retaining rib 38 acts to ensure that the straw may not roll backward along the carrying portion 36 to cause a possible jam. Only one straw may be dispensed at this time with each operation because of the provision for the pinch bar 44, which projects under the next succeeding straw so that it may not also be dispensed at the same time. Thus, as the pressure is released on the pressing pad 40, the resilience of the leaf springs 32 causes the dispensing member 24 to pivot from its dispensing portion to its rest position, carrying the dispensed straw on the carrying portion 36 beyond the retaining rib 38. The user may then remove the straw from the carrying portion 36 and use it for its intended purpose. As the dispensing member 24 pivots toward its rest position, the pinch bar 44 recedes away from the inside edge of the storage bin 12 so that the next succeeding straw may drop down onto the carrying portion 36 so as to be dispensed upon the next operation of the dispensing member 24.
The trouble free operation of the dispensing unit 10 is insured by the provision for the sorting tabs 42. The sorting tabs 42 prevent two straws at a time from occupying the position just above the pinch bars 44. This prevents the sort of jam that on occasion occurs in some dispensing machines when two articles both become wedged into opening wide enough to accommodate only one of the articles. In the dispensing unit 10, the only narrow passage is between the pinch bar 44 and the wall of the storage bin 12 and the sorting tabs 42 allow only one straw at a time to proceed down the support shelf 28 and over the pinch bars 44. Thus, an orderly line of straws awaiting to be dispensed is maintained at all times, and jam free operation is assured. The intermittant pivoting of the support shelf 28, in turn, insures that no straws are jammed between the sorting tabs 42 and the pinch bars 44.
In addition, the provision for the leaf springs 32 also helps to insure that the straws are properly aligned as they come toward the dispensing port 14. As can be seen in the right hand side of FIGS. 2 and 3, when the dispensing member 24 is rotated to its dispensing position, the leaf springs 32 are bowed, and extend up above the plane of the bottom bracket 20. These bowed portions of the leaf springs 32 jostle any straws which may be located in that portion of the storage bin 12. Straws so jostled tend to roll evenly down the bottom bracket 20 toward the dispensing member 24. This prevents any straws which may have a tendency not to roll, because of some uneven construction or some material adhering to their exterior, from not rolling down the bottom bracket and also helps to ensure that the straws are properly aligned as they arrive at the dispensing member 24.
Shown in FIG. 4 is an alternative arrangement for securing the dispensing member 24 in a pivotable manner in the dispensing unit 10. The dispensing member 24 shown in FIG. 4 is in all respects identical to the dispensing members 24 in FIGS. 1-3. However, the dispensing member 24 of FIG. 4, rather than being pivotally secured to the hinge tabs 22 on the bottom bracket 20, is pivotally secured to a separate bracket assembly 100. The bracket assembly 100, which is secured to the interior of the storage bin 12 through suitable bolts or other fastening means applied through holes 102, has a pair of hinge tabs 122 extending rearwardly from the ends thereof. The hinge tabs 26 of the dispensing member 24 are rotatably secured to the hinge tabs 122 of the bracket assembly 100. The bracket assembly 100 also includes the two sorting tabs 142 thereon, the sorting tabs 142 being formed as cut out and deformed portions of the bracket assembly 100. The dispensing member 24 as shown in FIG. 4 operates in a manner similar to that shown in FIGS. 1-3, with the difference between them being only in the manner in which the dispensing member 24 is mounted, and the manner in which the sorting tabs 142 are formed.
Shown in FIGS. 5 and 6 is another alternative embodiment of the present invention. In this embodiment a dispensing unit, generally indicated at 210, includes a storage bin 212 with a cover 216. In this embodiment, a bottom bracket 220 is pivotably mounted through the use of a pivot tab 221 which is secured to a bracket 223 attached to the bottom of the storage bin 212. The bottom bracket 220 thus is able to pivot about its forwardmost end. A dispensing member 224 is provided in the dispensing unit 210 and includes a pair of downwardly depending hinge tabs 226 which are pivotally secured to the interior side walls of the storage bin 212. Above the hinge tabs 226 a support shelf 228 is formed and a pair of spring arms 230 extend rearwardly from the rearward edge of the support shelf 228. Each of the spring arms 230 has a respective leaf spring 232 attached thereto with the other end of the leaf spring 232 resting against the underside surface of the bottom bracket 220. Also formed on the dispensing member 224 is a carrying portion 236 which terminates in a dispensing tab in an arrangement similar to the dispensing member 24 of FIGS. 1-3. Also similarly to the embodiment shown in FIGS. 1-3, a pair of pinch bars 244 extends forwardly from the support shelf 228, and a pair of sorting tabs 242 are provided mounted on the interior wall of the storage bin 212 above the dispensing member 224. At the end of the storage bin 212 opposite from the dispensing member 224, a retaining shield 250 is mounted inside of the storage bin 212. The retaining shield 250 is curved so as to correspond approximately with the travel of the rearward end of the bottom bracket 220.
In its operation the dispensing unit 210 of FIGS. 5 and 6 is very similar to the operation of the dispensing unit 10 of FIGS. 1-3. The main difference in its operation is the provision for the tilting bottom bracket 220. As can be seen in FIG. 6, when the dispensing member 224 is pivoted to its dispensing position, the leaf spring 232 acts on the bottom of the bottom bracket 220 to tilt the bottom bracket 220 so that the straws thereon roll toward the dispensing member 224. The retaining shield 250 acts to prevent the articles on the bottom bracket 220 from rolling beyond the reach of the bottom bracket 220. Otherwise the operation of the dispensing unit 210 is similar to that of the operation of the dispensing unit 10 of FIGS. 1-3.
It is understood that the present invention is not limited to the particular construction and arrangement of parts disclosed and illustrated herein, but embraces all such modified forms of the invention as come within the scope of the following claims. | A dispensing unit for elongated articles is disclosed including a pair of dispensing members which are operated by hand to dispense articles from a storage bin through a dispensing port. The dispensing members are structured so as to cooperate with the interior walls of the storage bin, and also with a sorting tab mounted on the interior thereof, to ensure that the articles waiting to be dispensed from within the unit are properly aligned in the storage bin adjacent the dispensing port so that jamming of the objects inside of the storage bin is prevented. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application No. 61/449,295, filed on Mar. 4, 2011. The entire disclosure of the above application is incorporated herein by reference.
FIELD
[0002] The present disclosure relates to monorail systems used in various applications, typically manufacturing and assembly operations, and more particularly to a monorail buss control system and method that can be implemented with less cost and complexity than previously developed monorail conveyor systems without sacrificing utility and efficiency of the system.
BACKGROUND
[0003] The statements in this section merely provide background information related to the present disclosure and may not constitute prior art.
[0004] Electrified monorail convey systems are often employed in assembly and manufacturing environments to move component parts from one location within an assembly environment (often a factory) to another station. Such systems generally are quieter and cleaner to operate than conveyor systems that use chains to pull part carriers along a predetermined path. However, electrified monorail conveyor systems have traditionally been fairly costly to implement, which has in some applications limited their applicability. Typical electrified monorail conveyor systems often include a plurality of tractor assemblies, sometimes referred to as “carrier” assemblies that are independently propelled along an electrified track. For simplicity these will be referred to simply as “tractor assemblies”. The tractor assemblies typically carry a part or subassembly thereon from one station of an assembly or processing facility to another station. Typically each tractor assembly has its own electronic controller that is mounted thereon, and uses control signals transmitted along one or more conductors extending along the track to control motion of its associated carrier assembly. Obviously, the need to include an electronic controller for each and every carrier assembly adds significant cost to the overall system.
SUMMARY
[0005] In one aspect the present disclosure relates to a modular, electrified monorail system upon which at least one motorized trolley assembly may be propelled along. The system may incorporate a plurality of rail assemblies adapted to be coupled adjacent to one another to form a generally continuous track. Each rail assembly may make use of an electrified track adapted to provide an electrical signal from an electrical power source to at least one electrical conductor extending coextensively along the electrified track. A controller may be mounted on the electrified track. The controller may be configured to selectively apply and remove the electrical power from the electrified track to control propulsion of the motorized trolley assembly along the electrified track.
[0006] In another aspect the present disclosure relates to a modular, electrified monorail system. The system may comprise a plurality of motorized trolley assemblies which are adapted to be propelled by electrical power. A plurality of rail assemblies may be included which are adapted to be coupled adjacent to one another to form a generally continuous track. Each rail assembly may include an electrified track adapted to provide an electrical signal from an electrical power source to at least one electrical conductor extending coextensively along the electrified track. The at least one electrical conductor may be adapted to provide the electrical signal to any one of the motorized trolleys that is present the electrified track. A controller may also be mounted on the electrified track. The controller may be configured to selectively apply and remove the electrical power from the electrified track to control propulsion of each of the motorized trolley assemblies along the electrified track. A remotely located controller may be included which is in communication with the controller located on each electrified track, for communicating with the controller on each one of the electrified tracks when to apply and remove power from its associated electrified track.
[0007] In still another aspect the present disclosure may relate to a method for forming a modular electrified monorail system. The method may comprise plurality of operations including providing a plurality of motorized trolley assemblies that each may be independently propelled via electrical signals. A plurality of rail assemblies may be used which are adapted to be coupled adjacent to one another to form a generally continuous track upon which the motorized trolley assemblies may be propelled. For each rail assembly, an electrified track may be used which is adapted to provide an electrical signal from an electrical power source to at least one electrical conductor extending coextensively along the electrified track. A controller may also be used which may be mounted on the electrified track. The controller may be caused to selectively apply and remove the electrical power from the electrified track to control propulsion of the motorized trolley assembly along the electrified track. A remotely located controller may be used to communicate with each of the controllers and to inform each of the controllers specifically when to apply electrical power to its associated said electrified track, and when to remove electrical power from its associated said electrified track, to control movement of the motorized trolleys along each of the electrified tracks.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way.
[0009] FIG. 1 is a side view of one embodiment of a modular, electrified monorail buss control rail system in accordance with the present disclosure that makes use of a plurality of modular, electrified monorail rail assemblies coupled adjacent to one another;
[0010] FIG. 2 is an enlarged perspective view of one of the modular rail assemblies shown in FIG. 1 ;
[0011] FIG. 3 is a simplified cross sectional view one of the trolley assemblies of the system taken along section line 3 - 3 in FIG. 2 ;
[0012] FIG. 4 is a simplified electrical schematic diagram showing how a logic controller is electrically in communication with each of the controllers of the rail assemblies; and
[0013] FIG. 5 is a diagram illustrating how movement of a trolley assembly occurs along a plurality of the rail assemblies.
DETAILED DESCRIPTION
[0014] The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses. It should be understood that throughout the drawings, corresponding reference numerals indicate like or corresponding parts and features.
[0015] Referring to FIGS. 1 and 2 , there is shown a modular, electrified, monorail system 10 that makes use of a plurality of identical electrified monorail rail assemblies 10 a , 10 b and 10 c . For convenience the electrified monorail rail assemblies 10 a - 10 c will be referenced simply as “rail assemblies” 10 a - 10 c . It will also be appreciated immediately that while only three complete rail assemblies 10 a - 10 c are shown in FIG. 1 , that in a typical application dozens or even hundreds or more such assemblies 10 may be coupled adjacent to one another and used to form the needed path of travel through an assembly plant or processing plant where the system 10 is being employed. The path of travel may include long straight lengths as well as turns and elevation changes. Conventional track switches may also be employed in connection with the rail assemblies 10 a - 10 c to route different components being carried along the rail assemblies 10 a - 10 c to different assembly or processing stations within an assembly or processing plant.
[0016] Since the rail assemblies 10 a - 10 c are identical in construction, only the construction of rail assembly 10 a will be described in detail. Rail assembly 10 a is shown in greater detail in FIG. 2 and includes a plurality of conventional yokes or hangers 12 that suspend an electrified track 14 from a support beam 16 . Typically the support beam 16 may employ a cable tray 18 to hold the various electrical cables (not shown) that are used in connection with the rail assembly 10 a . The cable tray 18 also supports T-couplings (not shown) where various electrical connections are made between the rail assembly 10 a components and the electrical cables running along the support beam 16 .
[0017] The rail assembly 10 a may also include a trolley assembly 20 in addition to an idler assembly 22 . Optionally, a plurality of idler assemblies 22 may be employed, which may depend in part on the overall length of the rail assembly 10 a and a load which it is expected to carry. A controller 24 is mounted on the track 14 in a manner that does not interfere with movement of the trolley assembly 20 and the idler assembly 22 . The controller 24 , in one embodiment, may be a well known integrated distributed controller that assists in controlling motion of the trolley assembly 20 and the idler assembly 22 . However, the system 10 is not limited to use only with integrated distributed controllers but rather may incorporate any other suitable form of controller capable of controlling the application of electrical power to the track 14 .
[0018] The rail assembly 10 a also include a first switch or sensor 26 and a second switch or sensor 28 . The first sensor 26 may also be viewed as a “clear” sensor because it senses the arrival of one of the trolley assemblies 20 as the trolley assembly moves along the track 14 of each rail assembly 10 . Clear sensor 26 indicates to the prior rail assembly (i.e., the rail system “upstream” of rail system 10 a ) that rail system 10 a is clear to receive a trolley assembly 20 . The second sensor 28 may be viewed as a “stop” sensor because it senses the trolley assembly 20 and turns power off to rail assembly 10 to stop the trolley assembly 20 . Sensors 26 and 28 may be conventional proximity sensors or any other suitable form of sensor or switch.
[0019] Referring further to FIG. 2 , each rail assembly 10 a - 10 c may also include a load bar 30 that supports a carrier 32 therefrom. The carrier 32 may be specifically adapted to hold one or more of a particular type of part. The load bar 30 may include conventional rubber bumpers 34 at opposing longitudinal ends thereof to cushion and protect the load bar.
[0020] An important advantage of the system 10 is that the rail assemblies 10 a - 10 c are modular in construction. By “modular” it is meant that each includes its own controller 24 and its own sensor 26 and 28 , in addition to all T-connectors that enable it to be quickly and efficiently coupled to the electrical cabling extending along the support beam 16 . By providing each track 14 with its own controller 24 , rather than including a separate controller on each trolley assembly 20 , a significant cost savings is realized without compromising the overall utility of the system 10 . The rail assemblies 10 a - 10 c may be provided in any suitable length that will be dictated at least in part by the needs of the specific application. However, it is anticipated that the rail assemblies 10 a - 10 c , in many applications, will each have an overall length between about four to six meters.
[0021] With brief reference to FIG. 3 a simplified cross-sectional view of the trolley assembly 20 is shown. The trolley assembly 20 may be viewed as a “drive” trolley because it provides the motive force to propel the load bar 30 and the carrier 32 along the tracks 14 of the track assemblies 10 a - 10 c . The trolley assembly 20 may include a frame portion 36 that supports a gear motor 38 thereon. The gear motor 38 is powered by a suitable power signal applied along electrified buss bars that extend along the track 14 of each rail assembly 10 a - 10 c . An exemplary power signal may be a 480 VAC power signal, although signals of other magnitudes may also be used. The frame portion 36 also includes a brush plate 40 and a sensor flag 42 . The sensor flag 42 is used to trip the sensors 26 and 28 as the trolley assembly 20 moves along the track 14 . The brush plate 40 engages a plurality of electrified buss bars 44 a - 44 c , as well as a ground buss bar 44 d , that extend along the track 14 . Upper and lower wheels 46 and 48 rotationally supported from the frame portion 36 enable smooth rolling motion of the trolley assembly 20 along the track. With brief reference to FIG. 2 , idler assembly 22 is a conventional component that includes a plurality of wheels supported from a frame portion 50 which enable rolling motion along the track 14 . The load bar 30 is fixedly secured to the frame portions 36 and 50 so that the trolley assembly 20 , the idler assembly 22 , the load bar 30 and the carrier 32 form a single assembly that is propelled along the track 14 of each rail assembly 10 a - 10 c by the gear motor 38 .
[0022] Referring briefly to FIG. 4 , a high level electrical schematic diagram is shown of rail assemblies 10 a - 10 c . A controller, for example a programmable logic controller 54 (hereinafter simply the “logic controller” 54 ), applies control signals to a control signal buss 56 that may in turn provide the signals to the controller 24 on each track 14 to assist the controller 24 in turning on and off power to its high power buss bars. An auxiliary control power signal (e.g., a 120 VAC signal) may be applied on a power buss 58 to power the controllers 24 mounted on each track 14 . A high voltage, three phase power signal may be applied on a power buss 60 that communicates with buss bars 44 a - 44 c (i.e., a three phase electrical signal using three buss bars for the three phases and one buss bar ( 44 d ) for ground) on the track 14 . The first and second sensors 26 and 28 of each track 14 are also electrically coupled to the controller 24 of their associated track 14 . T-couplings 62 and other plug in cables (not shown) are used as needed to make the required connections between the electrical cables and the controller 24 of each track 14 .
[0023] With reference to FIG. 5 , a sequence of operation of the system 10 will now be provided. For the purpose of discussion, the components including the trolley assembly 20 , the idler assembly 22 , the load bar 30 and the carrier 32 will be referred to collectively as the “carrier assembly” 64 . In operation, the carrier assembly 64 may initially be present on track 14 a of rail assembly 10 a . The controller 24 on rail assembly 10 c may supply a signal to the logic controller 54 ( FIG. 3 ) indicating that track 14 b is clear to accept carrier assembly 64 . The controller 24 on track 14 c knows this because a carrier assembly moving from track 14 b to 14 c actuated the track 14 c clear sensor 26 (i.e., sensing the presence of a carrier assembly). The logic controller 54 then applies a control signal to the controller 24 a of track 14 a and the controller 24 b of track 14 b instructing both controllers 24 a , 24 b to apply power to their high power buss bars (e.g., buss bars 44 a - 44 c ). This simultaneously causes the controllers 24 a and 24 b to turn on power to their respective high power buss bars 44 a - 44 c . When this occurs, power is applied through the high power buss bars 44 a - 44 c to gear motor 38 causing gear motor 38 to begin propelling the carrier assembly 64 in the direction of arrow 66 . The flag 42 mounted on the trolley assembly 20 will pass stop sensor 28 on track 14 a which informs the controller 24 a that the carrier assembly 64 is moving off of the track 14 a . The carrier assembly 64 will continue to travel to track 14 b . When the carrier assembly 64 passes the clear sensor 26 on track 14 b , then this information is sent to logic controller 54 which tells the controller 24 a to turn off power to the high power buss bars 44 a - 44 c on track 14 a if there is no carrier assembly present on the prior (i.e., upstream) track. However, power at this time remains turned on to the high power buss bars 44 a - 44 c of track 14 b by controller 24 b , which continues to power the gear motor 38 along the track 14 b . When the flag 42 trips the stop sensor 28 on track 14 b , the controller 24 b turns off the high power signal to its high power buss bars 44 a - 44 c , and the carrier assembly 64 will quickly coast to a stop within a predetermined distance after power is removed from the gear motor 38 .
[0024] Preferably, the flag 42 is selected to have a physical length such that the carrier assembly 64 will come to a complete stop within the length of the flag 42 . When the clear sensor 26 on track 14 b is tripped by the flag 42 , the controller 24 b on track 14 b will send a signal to the logic controller 54 on the control buss 56 ( FIG. 4 ). This signal indicates to the logic controller 54 that the carrier assembly 64 is presently located on its track 14 b and that track 14 a is clear to accept a carrier assembly 64 . The above sequence of operation then will be repeated but for rail assemblies 10 c and 10 b . Thus, the logic controller 54 will send a signal to the controller 24 c of rail assembly 10 c and to the controller 24 b of rail assembly 10 b that the carrier assembly 64 may be moved onto rail assembly 10 c . The controller 24 b will then apply power to its high power buss bars 44 a - 44 c on track 14 b while controller 24 c applies power to its high power buss bars 44 a - 44 c on track 14 c . The gear motor 38 will then propel the carrier assembly 64 from track 14 b to track 14 c.
[0025] From the foregoing it will be appreciated that the system 10 provides a highly cost efficient alternative to traditional electrified monorail assemblies that require the use of a dedicated controller on each carrier assembly. The present system 10 and method, because of its significantly lower cost and ease of installation, is expected to find utility in many applications where a traditional electrified monorail assembly would have been too costly to implement. Furthermore, since the system 10 is modular in its construction, the rail assemblies can easily be made to specific lengths to suit the particular needs of each application.
[0026] While various embodiments have been described, those skilled in the art will recognize modifications or variations which might be made without departing from the present disclosure. The examples illustrate the various embodiments and are not intended to limit the present disclosure. Therefore, the description and claims should be interpreted liberally with only such limitation as is necessary in view of the pertinent prior art. | A modular, electrified monorail system upon which at least one motorized trolley assembly may be propelled along. The system may incorporate a plurality of rail assemblies adapted to be coupled adjacent to one another to form a generally continuous track. Each rail assembly may make use of an electrified track adapted to provide an electrical signal from an electrical power source to at least one electrical conductor extending coextensively along the electrified track. A controller may be mounted on the electrified track. The controller may be configured to selectively apply and remove the electrical power from the electrified track to control propulsion of the motorized trolley assembly along the electrified track. | 8 |
exposing the substrate to relatively low temperatures. The present method comprises contacting the heated substrate surface with a stream of ozone (O 3 ) while evaporating the other (metallic) components of the superconductive ceramic oxide onto the surface, so that a layer of a superconductive ceramic oxide is formed thereon. The metallic components are oxidized in situ by active oxygen atoms (O*) formed by thermal decomposition of the O 3 at the heated surface. Preferably, the ozone is produced by the evaporation of an external source of liquid ozone, which is then introduced into a vacuum chamber containing sources of the other components and the substrate.
The use of essentially pure ozone to provide oxygen atoms for the superconductive lattice allows production of superconductive films of the correct crystal structure, chemical composition and superconductive properties without the need to post anneal the ceramic or to subject it to any additional treatment. The present method can be carried out at about 500°-700° C., preferably at about 450°-500° C., temperatures which permit the formation of superconductive layers on substrates, such as plastics, certain metals, or single crystals of silicon or GaAs, which could not heretofore be used. The layers can also be deposited to virtually any desired thickness, e.g., from about 500 Å to 0.5 μm.
With minor modifications, the present method can be employed to prepare any of the known superconductive ceramic oxides. The structures of three of the most widely-investigated classes of these materials is summarized in Table I, below. Other superconductive ceramic oxides which can be used as substrates in the present method are described hereinbelow.
TABLE I______________________________________Superconductive Ceramics Abbrevi-Formula X Y ation______________________________________La.sub.2-x A.sub.x CuO.sub.4 0.07 - 0.2 -- 2-1-4.sup.1, 4RZ.sub.2 Cu.sub.3 O.sub.7-x 0 < x < 1 -- 1-2-3.sup.2, 5Bi.sup.II Ca.sub.1+x Sr.sub.2-x Cu.sub.2 O.sub.8+y 0 < x < 1 0 < Y < 2 2-1-22.sup.3Tl.sup.II Ca.sub.x-1 Ba.sub.2 Cu.sub.x O.sub.2x+3 X = 1, 2 or 3 -- 1-(X-1)-(2)(X)______________________________________ .sup.1 J. G. Bednorz et a1., Z. Phys. B., 64, 189 (1986), (A = Sr). .sup.2 C. W. Chu et al., Phys. Rev. Lett., 58, 405 (1987), (R = Y). .sup.3 H. Maeda et a1., Jpn. J. Appl. Phys., 27, L209 (1988); Z. Z. Sheng et al., Nature, 332, 55 (1988). .sup.4 A = Ba, Sr, Ca. .sup.5 R = lanthanide element, i.e., Y, Sm, Eu, Gd, Dy, Ho, Yb when Z = Ba; also YSr.sub.2 Cu.sub.3 O.sub.7-x.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic depiction of a multisource high vacuum system equipped with two electron guns (e-guns 1 and 2) and a K cell, which can be used to practice the present method.
FIG. 2 is a graphical depiction of the superconductive transition temperature (Tc) of a film of YBa 2 Cu 3 O 7-x prepared in accord with the present method.
FIG. 3 is the x-ray diffraction pattern obtained for a c-axis oriented film of YBa 2 Cu 3 O 7-x prepared in accord with the present method.
DETAILED DESCRIPTION OF THE INVENTION
Ceramic Superconductors
Superconducting oxides have been known since 1964, but until recently, the intermetallic compounds showed higher superconducting temperatures. In 1975, research scientists at E. I. DuPont de Nemours discovered superconductivity in the system BaPb 1-x Bi x O 3 with a Tc of 13K (A. W. Sleight et al., Solid State Commun., 17, 27 (1975)). The structure for the superconducting composition in this system is only slightly distorted from the ideal cubic perovskite structure. It is generally accepted that a disporportionation of the Bi(IV) occurs, namely, 2Bi(IV)(6s 1 )→Bi(III)(6s 2 )+Bi(V)(6s 0 ) at approximately 30 percent Bi. Sleight et al. found that the best superconductors were single phase prepared by quenching from a rather restricted single-phase region, and hence these phases are actually metastable materials. At equilibrium conditions, two phases with different values of x would exist; the phase with a lower value of x would be metallic and with a higher value of x would be a semiconductor. It is important to keep in mind that the actual assignment of formal valence states is a convenient way of electron accounting; the actual states include appreciable admixing of anion functions. Recently, for example, Cava and Batlogg, Nature, 332, 814 (1988), have shown that Ba 0 .6 K 0 .4 BiO 3 gave a Tc of almost 30K, which is considerably higher than the 13K reported for BaPb 0 .75 Bi 0 .25 O 3 .
La 2 CuO 4 was reported by Longo and Raccah, J. Solid State Chem., 6, 526 (1973), to show an orthorhombic distortion of the K 2 NiF 4 structure with a=5.363 Å, b=5.409 Å and c=13.17 Å. It was also reported that La 2 CuO 4 has a variable concentration of anion vacancies and may be represented as La 2 CuO 4-x . Superconductivity has been reported for some preparations of La 2 CuO 4 . See D. C. Johnston et al., Phys. Rev. B, 36, 4007 (1987). However, there appears to be some question as to the stoichiometry of these products since only a small portion of the material seems to exhibit superconductivity (P. M. Grant et al., Phys. Rev. Letters, 58, 2482 (1987)).
In the La 2-x A x CuO 4 ceramics (A=Ca, Sr, Ba), the substitution of the alkaline earth cation for the rare earth depresses the tetragonal-to-orthorhombic transition temperature. The transition disappears completely at x>0.2, which is about the composition for which superconductivity is no longer observed.
The compound Ba 2 YCu 3 O 7 shows a superconducting transition of about 93K and crystallizes as a defect perovskite. The unit cell of Ba 2 YCu 3 O 7 is orthorhombic (Pmmm) with a =3.8198(1) Å, b=3.8849(1) Å and c=11.6762(3) Å. The structure may be considered as an oxygen-deficient perovskite with tripled unit cells due to Ba-Y ordering along the c-axis. For the Ba 2 YCu 3 O 7 , the oxygens occupy 7/9 of the anion sites. One-third of the copper is in four-fold coordination and two-thirds are five-fold coordinated. A reversible structural transformation occurs with changing oxygen stoichiometry going from orthorhombic at x=7.0 to tetragonal at x=6.0 (see P. K. Gallagher et al., Mat. Res. Bull., 22, 995 (1987)). The value x=7.0 is achieved by annealing in oxygen at 400°-500° C., and this composition shows the sharpest superconducting transition.
Recently, Maeda et al., cited above, reported that a superconducting transition of 110K was obtained for Bi 2 Sr 2 CaCu 2 O 8 . In most of the studies reported to date on the Bi/Sr/Ca/Cu/O system, measurements were made on single crystals selected from multiphase products. The group at DuPont selected platy crystals having a composition Bi 2 Sr 3-x Ca x Cu 2 O 8+y (0.9>x>0.4) which showed a Tc of about 95K. Crystals of Bi 2 Sr 3-x Ca x Cu 2 O 8+y for x=0.5 gave orthorhombic cell constants a=5.399, b=5.414, c=30.904 (M. A. Subramanian et al., Science, 239, 1015 (1988)). The structure consists of pairs of CuO 2 sheets interleaved by Ca(Sr), alternating with double bismuth-oxide layers.
There are now three groups of superconducting oxides which contain the mixed Cu(II)-Cu(III) oxidation states, namely La 2-x A x CuO 4 where A II =Ba +2 , Sr +2 or Ca +2 ; RBa 2 Cu 3 O 7 where R is almost any lanthanide; and Bi 2 Sr 3-x Ca x Cu 2 O 8+y . Z. Z. Sheng and A. M. Herman, Nature, 332, 55 (1988) have recently reported a high-temperature superconducting phase in the system Tl/Ba/Ca/Cu/O. Two phases were identified by R. M. Hazen et al., Phys Rev. Letters, 60, 1657 (1988) namely Tl 2 Ba 2 CaCu 2 O 8 and Tl 2 Ba 2 Ca 2 Cu 3 O 10 . A. W. Sleight et al. J. Solid State Chem., 76, 432 (1988) and Nature, 332, 420 (1988), have also reported the structure Tl 2 Ba 2 CaCu 2 O 8 as well as Tl 2 Ba 2 CuO 6 . In addition, superconductor Tl 2 Ba 2 Ca 2 Cu 3 O 10 has been prepared by the IBM group and shows a Tc of 125K. TaBa 2 Ca 3 Ca 4 O x may exhibit a Tc as high as 160K.
A series of oxides with high Tc values has now been studied for the type (A III O) 2 A 2 II Ca n-1 Cu n O 2+2n , where A.sup.(III) is Bi or Tl, A.sup.(II) is Ba or Sr, and n is the number of Cu-O sheets stacked. To date, n=3 is the maximum number of stacked Cu-O sheets examined consecutively. There appears to be a general trend whereby Tc increases as n increases.
There are compounds of Y, Ba, Cu and O in the 2-4-8 structure (Y 2 Ba 4 Cu 4 O 20-x ). Presumably, these can also form with rare earths substituted for Y. In the case of all of these compounds, they can be formed with different amounts of oxygen. Some of these materials have reduced transition temperatures or are insulators with very high dielectric constants.
There are various Bi-Ba-Sr-Cu-O compounds with various transition temperatures starting at about 50K and going up to 110K, depending on the details of the particular crystal structure and chemical composition (Bi 2 Sr 2 CuO 6 ±Y, Bi 2 CaSr 2 Cu 2 O 8 ±Y).
The Pb-Bi-Ba-O compounds which are cubic Perovskites, and all of their variants and substitutions are also possible products of the present method. These materials have reduced transition temperatures relative to the 1-2-3 compounds, the Bi and Tl compounds described above.
In principle, the present method could be used to produce other oxides in thin film form. This would include insulating and piezoelectric ceramics of various types. There are many examples where a common element is substituted onto one of the sites in the lattice of a high temperature superconductor, usually resulting in the depression or even complete suppression of the superconducting transistion temperature. All of these materials can be prepared using the present method. An example is the replacement of Cu by Ag or Al.
Substrates
Although the present method is exemplified using SrTiO 3 as a substrate, a wide variety of substrates can be employed including, but not limited to, materials useful in semiconductor technology, such as GaAs(100), GaAs(111), GaAs(110), Si(111), Si(311), Si(100) and the like. Oxides such as crystalline Al 2 O 3 , amorphous Al 2 O 3 , MgO and ZrO 2 can also be used, as can nitrides, such as silicon nitride. The deposition temperatures of the present method are low enough so that plastic substrates such as Mylar or Kapton and polyimides can also be used, resulting in flexible superconductive structures. Stainless steel substrates can also be employed.
Vacuum Evaporation Apparatus
A preferred evaporation system to carry out the present method is schematically depicted in FIG. 1, and is similar to the system described by R. J. Webb and A. M. Goldman, "An Evaporation System for the Preparation of Ternary Compounds," J. Vac. Sci. Technol., A3 (5), 1907 (1985), the disclosure of which is incorporated by reference herein. As shown in FIG. 1, the substrate(s), evaporation sources and rate monitors are contained within an ultrahigh vacuum chamber. This main chamber is pumped by a Varian VK-12 closed-cycle, helium-refrigerated cryopump, with a speed of 1000 l/s. In addition, there are ion pumps with a combined speed of 400 l/s. The chamber is lined with a thin-walled stainless steel shroud (not shown) which is filled with liquid nitrogen during the evaporation, in order to provide extra pumping and to capture stray evaporant. The chamber is also fitted with heating collars which allow it to be baked at a temperature of approximately 150° C. (not shown).
A separately pumped load lock chamber is attached to the main chamber, via a gate valve (x), and is used to change substrates between evaporations. This antechamber precludes the necessity of opening the main chamber to the atmosphere between runs. Using the antechamber, changing the substrates takes about 1 hr, and background pressures before a run are typically about 5×10 -8 Torr.
This system contains two 7 cc electron beam guns (Edwards-Temescal) and one Varian Knudsen Cell (K-cell) (GEN-II 40 cc). The substrate heater (two tungsten filaments inside a stainless steel block) provides substrate temperatures from 0° C. to 1100° C. by heating radiatively from the back.
As depicted, the apparatus uses ozone which is generated, collected in a still in essentially pure liquid form and dispensed into the vacuum chamber so that at least about 10 15 molecules of O 3 /sec reach the substrate surface. Any source of ozone which produces a flux of molecules comparable to the deposition rate would work as well. Ozone can also be introduced into a sputtering system to facilitate the formation of the oxides. In sputtering systems, a compound or composite target or separate targets are bombarded with ions to produce neutral beams which are then collected on a substrate.
The invention will be further described by reference to the following detailed example.
EXAMPLE. PREPARATION OF YBa 2 Cu 3 O 7-X FILMS
A. Evacuation and Loading of the Vacuum Chamber
The vacuum chamber pressure is reduced to 10 -8 Torr at the start of the process. To achieve this pressure after the vacuum chamber has been at atmospheric pressure, the turbomolecular pump ("turbo pump") is used to pump the vacuum chamber down from atmospheric pressure to 10 -3 Torr. This takes about 12 to 16 hours. The gate valve (x) to the cryopump is opened, and the chamber is pumped down to 10 -5 to 10 -6 Torr over a period of two days. The ion pump is turned on when the pressure falls below 10 -5 Torr. The evaporation sources are outgassed. The Knudsen cell (K-cell) is heated to approximately 1150° C. The electron guns (e guns) are operated with the electron beams scanning over the entire charge of evaporation source material at a frequency of 60 Hz with a beam current of approximately 0.1 Amperes. Outgassing of the sources is carried out for approximately one hour for each evaporant source.
After this procedure is followed, the vacuum chamber is pumped by the cryopump and ion pump 24 hours a day. The number of films that can be manufactured before opening the vacuum chamber to atmospheric pressure is limited only by the lifetime of the quartz crystal rate monitors (QCMs) and the evaporant available in the sources.
After the vacuum chamber has reached a pressure of 10 -8 Torr, the cryoshroud and the QCMs are cooled in the vacuum chamber with liquid nitrogen. Liquid nitrogen is flowed continuously through the cryoshroud and the QCMs during the deposition of a film. Each film deposition requires about 50 liters of liquid nitrogen over a 3-hour time period. Liquid nitrogen is supplied to the cryoshroud through a partially opened valve from a 160 liter Dewar flask having an internal pressure of about 20 psi. Liquid nitrogen is supplied to the QCMs from a 25 liter storage Dewar flask at an overpressure of about 3 psi. The QCMs are cooled to prevent overheating of the quartz crystal in the presence of the evaporation sources.
After the liquid nitrogen has begun to cool the cryoshroud and the QCMs, the Knudsen cell heater is turned on, and adjusted to a current of 2 Amperes. This begins the heating of the copper evaporant, a process which takes approximately one hour. The heater current is increased in several increments over this time, to a maximum of 4.25 Amperes. This produces a reading of about 22 millivolts on the Tungsten/5% Rhenium thermocouple attached to the Knudsen cell. The substrate is a 0.25 inch×0.25 inch×0.020 inch single crystal of strontium titanate having a polished (100) surface. The surface is polished by Commercial Crystal Laboratories, Naples, Florida, U.S.A., from where the substrate was purchased.
The substrate is cleaned ultrasonically in baths of toluene, acetone, and alcohol, respectively, for about 10 minutes in each bath, and dried in air.
The substrate is inserted into a stainless steel substrate holder with the shiny polished side down, to face the evaporation sources. In the slot in the substrate holder, two pieces of quartz (0.040 inches thick) are inserted, one on each side of the strontium titanate. The material deposited on these quartz pieces is used to measure the stoichiometry of the deposited film, using Direct Coupled Plasma-Atomic Emission Spectroscopy (DCP-AES). DCP-AES analysis of bare strontium titanate substrates detects enough barium to make it impossible to get an accurate measure of the amount of barium in the superconducting film deposited on the strontium titanate. Hence, quartz is used as a control substrate to measure the stoichiometry of the deposited films. To hold the substrates in place, a sapphire slab 0.020 inches thick is inserted over the strontium titanate and the quartz, and a piece of boron nitride is placed over the sapphire. The boron nitride is held in place by two 0-80 screws. The boron nitride has a slot which allows the sapphire to be directly exposed to thermal radiation from the substrate heater that is positioned above the substrate holder in the vacuum chamber.
The substrates and the holder are placed into the load lock chamber. This is accomplished by attaching the substrate holder to the magnetically driven vacuum manipulator by screwing the substrate holder onto the manipulator. The flange is then put in place on the o-ring seal on the load lock chamber and the screws are tightened to get a good vacuum seal. The majority of the air in the load lock chamber is then pumped out in about 10 seconds using a mechanical pump. The valve to the mechanical pump is then closed and the valve to the turbomolecular pump is opened. After approximately five minutes, the gate valve to the main vacuum chamber is opened and the valve to the turbomolecular pump is closed.
The substrate is loaded into the carousel in the main vacuum chamber. This is done by moving the substrate holder, using the magnetic manipulator, into the slot in the carousel. When the substrate holder is engaged in the carousel slot, the magnetic manipulator is unscrewed from the substrate holder and pulled back into the load lock chamber. The gate valve between the main vacuum chamber and the load lock chamber is then closed. Above this carousel slot is the substrate heater, which radiatively heats the substrate. Below this slot is the substrate shutter which, when closed, prevents material from being deposited on the substrate. The tube that injects ozone onto the substrate is anchored to the carousel and points at the substrate from below. On FIG. 1, the direction of O 3 flow from the generator to the still to the substrate surface is indicated by →.
Next, the substrate heater is turned on. The heater power is increased in increments over a period of approximately 30 minutes to 600° C. Typically, the heater current is increased from 20 Amperes to 30 Amperes, and then to 40 Amperes. The heater current is read on an AC inductive type current meter clamped to one of the wires leading to the substrate heater.
B. Ozone Production and Delivery
The ozone was produced and stored prior to the growth of a film, using a two-step process. First, zero grade oxygen was passed at 10 psi through an Orec silent discharge ozone generator powered by a 15 KV neon sign transformer (110 volts, 0.8 amp). The resulting gas was a 5% mixture of O 3 and O 2 which was leaked into a glass ozone still maintained at 77K and backpumped to a pressure of approximately 20 Torr using a sorption pump. The large difference in vapor pressures between O 2 and O 3 at 77K facilitates their separation in this way. After approximately 15 minutes, enough ozone was liquified to use during the evaporation. (Ozone is a deep purple, the quantity of which is easily judged by eye.) The liquid was then valved off from the still and accumulated O 2 was pumped away to leave pure liquid O 3 with a vapor pressure of 3 mTorr.
Because the vapor pressure of ozone is an exponential function of the temperature (3 mTorr at 77K and 40 mTorr at 87K), any desired pressure can be obtained in the gas handling system by carefully heating the still tube. The flow of O 3 to the substrate was maintained by regulating this pressure. This was accomplished by using a nichrome heating wire wrapped around the still and insulated from direct contact with the liquid nitrogen by inserting the still in an open test tube placed over the still. A Fe-Ni thermometer was placed underneath the nichrome wire and a feedback loop was used to carefully regulate the temperature. Typically, the pressure above the liquid ozone during evaporation was maintained at a value between 100 mTorr and 150 mTorr.
C. Deposition of Superconductive Layer
Next, the electron gun power supplies are turned on, and the high voltage for the electron guns is turned on. The power supplies that provide the longitudinal and lateral electron beam scanning are also turned on. Scanning the electron beam over the evaporant produces a more stable evaporation rate by reducing the temperature gradients that are present in the partially melted evaporant material. Next, the filaments for gun #1 (to deposit barium) and gun #2 (to deposit yttrium) are turned on, producing low power electron beams.
At this point, the valve between the ozone still and the main vacuum chamber was opened and the ozone stream is applied to the substrate through a 0.635 cm diameter Pyrex tube which was connected to a Teflon tube running to a UHV feedthrough. The ozone flow rate is regulated by heating the liquid ozone in the still in order to raise the vapor pressure of the ozone to between 100 mTorr and 150 mTorr, as measured by the capacitance manometer pressure guage. As the system is presently configured, a pressure larger than 150 mTorr at the ozone still will produce a flux of ozone into the chamber which is sufficiently large to cause the evaporation rates from the electron guns to be unstable. Larger ozone fluxes could be tolerated if a differential pumping configuration were employed, allowing a large pressure difference between the substrate region, where oxidation is desirable, and the region of the electron guns, where a low pressure is desirable.
To control and monitor the deposition rates, the program MAKEFILM is run on the personal computer. This program controls the electron gun evaporation rates by monitoring the QCMs for all the sources and using a proportional-integral-derivative (PID) feedback loop to control the electron gun filament currents, and hence the electron beam currents. The yttrium and barium deposition rates are controlled independently of each other. The QCM for the copper evaporation source is monitored by the computer, but the computer does not apply feedback to control the copper deposition rate, since the Knudsen cell provides a very stable evaporation rate without control by active feedback. The computer displays the deposition rates measured by all evaporation rate monitors, the feedback voltage being applied to each source, and the status of all feedback control loops. The possible source statuses are "not used", "idle", "ramping", "soak" (hold the feedback voltage at a fixed value), and "PID control".
Next, the yttrium electron gun beam current is raised using the computer to control the filament current. Initially, the status of the barium and yttrium electron gun control loops are "idle". The status of the yttrium electron gun is changed from "idle" to "ramping", and the power supply for gun #2 (yttrium) is switched from "local" to "remote", thus allowing the computer to control the evaporation rate. After one or two minutes, the feedback voltage for the yttrium electron gun rises high enough to yield a deposition rate that is detectable on the QCM that monitors the yttrium evaporation rate. The shutter below the substrate remains closed, so no material is deposited on the substrate. The computer will automatically change the status of the yttrium electron gun feedback to "PID control" when the deposition rate as measured on the yttrium QCM reaches a measurable value. Within about one minutes, the yttrium evaporation rate should be relatively stable. If the evaporation rate is very low, it is necessary to adjust the position of the electron beam, using the longitudinal and lateral control power supplies, so that the electron beam hits the yttrium in the crucible. This adjustment is facilitated by a viewport on the vacuum chamber.
After the yttrium electron gun provides a measurable deposition rate, the barium electron gun beam current can be raised using the same procedure as was followed for the yttrium electron gun. Both electron guns can be viewed through the same viewport.
The shutter below the substrate is opened when the yttrium and barium electron guns are both yielding stable evaporation rates (this may take several minutes after the deposition rates are ramped up), the copper deposition rate is at the desired value, and the substrate heater current has been at a steady value for at least twenty minutes (to allow the substrate temperature to stabilize). When the substrate shutter is opened, material from the evaporation sources begins to deposit onto the substrate.
During evaporation, pressures were maintained between 10 -7 and 10 -6 Torr at the ion pump. The background pressure of the system is 2×10 -8 Torr. Evaporations lasting about 10 minutes, with an average evaporation rate of 0.3 nm/sec and total thicknesses of 200-300 nm were typical for these films. Immediately after the evaporation was complete, power to the substrate heater was switched off and the ozone was allowed to flow at the nominal rate used during the evaporation for at least 30 minutes and, at most, 60 minutes.
The substrate holder is removed from the vacuum chamber by the magnetic manipulator, through the load lock chamber, and the substrates with the YBa 2 Cu 3 O 7-x films are removed from the substrate holder.
D. Characterization of YBa 2 Cu 3 O 7-x Films
FIG. 2 is a graph of resistance versus temperature of a typical YBa 2 Cu 3 O 7-x film of about 1800 Å. The plot shows a superconducting transition onset at 87K and a zero resistance at 82K. It was prepared using an ozone pressure in the gas-handling system between 115 mTorr and 117 mTorr. The ozone flow rate was estimated to be 10 15 molecules/sec. Evaporation time was 11 minutes. Current supplied to substrate heater was maintained at 40 Amperes during evaporation which corresponds to a substrate temperature of approximately 600° C. Evaporation rates for each of the sources as measured by quartz crystal monitors above each source were as follows: Barium rate=1.50 Å/sec; Yttrium rate=0.30 Å/sec; and Copper rate=2.5 Å/sec. The pressure in the evaporation system was maintained at between 10 -7 and 10 -6 Torr at the ion pumps during evaporation of the film.
FIG. 3 depicts the nearly ideal x-ray diffraction pattern of a c-axis oriented film of the YBa 2 Cu 3 O 7-x tested in FIG. 2. A Siemens D-500 diffractometer using copper k-alpha radiation was employed. These two figures indicate that the film possesses the correct crystal structure and has nearly ideal superconductive behavior.
E. Discussion
The present process can produce films of the correct crystal structure, chemical composition, and superconducting properties, without any post anneal or additional treatment. The correct lattice forms during deposition. The present process has been demonstrated to work at temperatures as low as 470° C. and will probably function at lower temperatures, e.g., as low as 400°-450° C. It can thus be used on substrates which are incompatible with higher temperature processing. Because the correct structure forms continuously, and at low temperatures, subsequent in situ processing is possible.
It may be possible to form composition-modulated structures where the composition is varied across the thickness of the film. This could permit the growth of single crystal tunneling structures which could comprise superconductor-insulator-superconductor junctions, and multilayer structures of alternating superconducting and insulating or superconducting and metallic layers. The insulator could be BaF 2 or CaF 2 , or some other suitable inert material. The fabrication of such tri-layer devices might be accomplished by replacing one of the constituents of a high temperature superconductor during the deposition with another element which produces an insulator. An example is the replacement of Y with Pr in the "1-2-3" compound. The resultant Pr compound is an insulator. In principle, a trilayer or multilayer can be grown as a single crystal.
If a superconductive layer is coated with an insulator by the above method, and then covered with a superconducting gate, it may be possible to produce a field effect transistor (FET) device in which the bias on the gate controls the carrier concentration in the superconductor and switches it in and out of the superconducting state.
The above device structures would follow naturally from the process since the formation temperature is low and no high temperature annealing is necessary. Because of this, it may be possible to produce the relatively sharp interfaces needed in these structures.
The invention has been described with reference to various specific and preferred embodiments and techniques. However, it should be understood that many variations and modifications may be made while remaining within the spirit and scope of the invention. | A low-temperature method is provided to prepare a superconductive ceramic oxide comprising contacting the surface of a heated substrate with ozone while evaporating the other components of the superconductive ceramic oxide onto said surface, so that a layer of the superconductive ceramic oxide forms thereon. | 8 |
FIELD OF THE INVENTION
The present invention is in the field of hunting blinds of the type used by deer hunters.
BACKGROUND OF THE INVENTION
Deer hunters often use hunting blinds to hide themselves in locations on the ground near expected deer paths. The blind usually has at least one “wall” formed from natural materials at hand such as sticks and foliage, or from dull-colored blankets or burlap material hung between poles or on a frame, or from plywood or lumber. The blind may be a portable camouflaged tent, or even an abandoned appliance or vehicle to whose presence deer have become accustomed. Blinds may be but one wall between the hunter's hiding spot and the deer, or may partially or fully surround the hunter for concealment from several angles or for weather protection in the colder fall and winter seasons when most deer hunting takes place. More elaborate blinds with shingled roofs, doors, sliding or hinged windows, chairs and benches are common, permanently located for use year after year.
Because hunters have long recognized that hunting from above the deer's field of vision is advantageous, treestands are also popular, especially with bowhunters. Treestands are platforms, often of metal or plastic grating or mesh, mounted in trees. They are typically small and portable, with room for a single hunter to stand or sit. These open platforms must be used with caution, since a fall can be serious, and they often are used with safety belts or harnesses in case a hunter loses his balance or nods off in his perch. Treestands tend to be favored by bowhunters because bowhunting often takes place in warmer weather and the stands are exposed to the elements, and because bowhunters need more space to nock arrows, draw, and shoot than do firearm hunters.
One approach taken by rifle hunters has been to build tower-type blinds that allow them to sit all day in relative comfort and greater safety well above the ground. These are usually expensive, heavy, and cumbersome, and if designed to be taken down at the end of a season require significant labor and transport. Firearm hunters have also used tree-house type blinds built directly into trees.
BRIEF SUMMARY OF THE INVENTION
The present invention is a walled, blind-style hunting enclosure removably mounted to the side of a tree in cantilever fashion. The enclosure is fully walled and in a preferred version is also roofed, yet is lightweight, easy to put up, and easy to take down. One wall of the enclosure is mounted adjacent the side of the tree trunk, while another wall has door access from a ladder. The blind and its cantilever support are designed to be assembled at the base of the tree to which it is to be mounted, and hauled vertically up and down the side of the tree trunk to be placed and secured in the desired hunting position.
Once installed against the trunk of a tree, the blind is supported entirely by the tree, and requires no supplemental supports. This allows the blind to move freely with the tree, for example in windy conditions.
The cantilever support is adapted to be fastened to the tree trunk at ground level to allow the blind to be assembled on it safely and conveniently, and then to guide the assembled enclosure vertically up the side of the trunk to a point where it can be refastened in its hunting position.
The walls of the blind are preferably formed in foldable, removable sections, for example foldable pairs, reducing assembly and disassembly time and making them easier to transport to and from the blind site. In one embodiment the floor of the blind is also foldable, and includes a channel defining the final shape of the blind and adapted to receive and align the wall sections accordingly.
In the roofed embodiments, the roof can be angled or gabled to keep water from dripping (and then freezing) onto the ladder. Windows that can be adjusted and opened from inside the enclosure are provided on each wall, including a wall facing the tree trunk.
These and other features and advantages of the inventions disclosed herein will become apparent upon further reading of the specification in light of the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front perspective view of a tree-mounted blind according to the invention, viewed from an angle below the level of the blind.
FIG. 2 is a side elevational view of the blind of FIG. 1 .
FIG. 3 is a top plan view of the blind of FIG. 1 , with the tree trunk sectioned.
FIG. 4 is a rear elevational view of the blind of FIG. 1 .
FIG. 5 is a bottom plan view of the blind of FIG. 1 .
FIG. 6 is a front perspective view of an alternate embodiment of a blind according to the invention, viewed from an angle below the level of the blind.
FIG. 7 is an exploded perspective view of the cantilever blind support from FIGS. 1–6 relative to the tree, and of the main assembly sections of the blind of FIG. 6 relative to the support.
FIG. 7A is a top plan view of the base/floor of the blind of FIG. 6 .
FIG. 7B is a bottom plan view of the base/floor of the blind of FIG. 6
FIG. 7C is a top plan view of the roof of the blind of FIG. 6 .
FIG. 8 is a side elevational view of the assembled blind and support of FIG. 1 , showing it positioned at the bottom of the tree in solid lines, and in its raised position in broken lines.
FIG. 9 is a front perspective view of an open-topped blind according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1 , a tree-mounted blind enclosure 10 according to the invention is shown mounted on a tree 28 , for example between ten and twenty feet off the ground. Blind 10 is an enclosed structure, in the illustrated example a fully walled rectangular structure with front wall 12 , side walls 14 and 16 , and rear wall 18 , all formed from suitable wood such as plywood with appropriate internal framing. It will be understood that the invention is limited neither to a rectangular shape nor to wood construction, although for most purposes this combination will not only be adequate but preferred. Walls made from other rigid materials such as plastics or even metals are possible, although wood is believed to be the best material. And as described in FIG. 6 below, other walled shapes such as hexagons may be desirable for certain features or appearances.
Each wall is provided with a window 12 a , 14 a , 16 a , 18 a , openable from the inside of the blind in known manner. Two possible examples include partitioned sliding windows, and hinged windows that drop down when a latch is released.
Blind 10 has a solid floor 20 and a solid roof 22 , for example also made from plywood and suitable framing members, thus providing a complete, weatherproof enclosure for a hunter in the tree. Access to the inside of blind 10 is through a door 24 formed in front wall 12 , reached by ladder 30 depending from front wall 12 . The ladder is preferably secured in place during the hunting season, but can also be removed and stored as desired between uses. The door can be placed in walls other than the front wall, depending on the desired angle of ladder access to the blind.
As shown in FIGS. 1 and 2 , blind 10 is mounted in cantilever fashion to the side of the trunk of tree 28 , supported on a generally L-shaped cantilever mount 26 so as to have rear wall 18 essentially squarely mounted next to the tree trunk. The floor of the blind rests on and is secured to horizontal cantilever arm portion 26 a (in the illustrated embodiment comprising a pair of spaced, parallel wooden rails). Vertical support portion 26 b is removably secured against the side of tree 28 via lower and upper anchor blocks 26 c and 26 d tensioned laterally against the tree trunk with suitably strong cables, chains, or straps 26 e . Triangular bracing 25 is added to the L-shaped cantilever support for strength.
Blind 10 is accordingly supported in cantilever fashion directly adjacent the vertical tree trunk, essentially paralleling the trunk for an unobstructed view (and shooting, when the windows are opened) in all directions except through the back wall, which faces the tree trunk. Even then, rear wall 18 is provided with a full width window that in most cases will be wider than even large diameter tree trunks for a partial view and/or shooting field to either side of the trunk. If the blind is fastened to an exceptionally large tree trunk whose diameter is equal to or greater than the width of the rear window (a rarity in today's forests), the flat, squared relationship of the windowed wall to the rounded trunk, along with the spacing of the rear wall from the trunk due to the thickness of the cantilever support's anchor blocks, will provide at least some field of vision to either side of the trunk through the rear window.
It will be understood that the terms “horizontal”, “vertical”, and “parallel” used above in reference to the relationship of the cantilever support are used in a general and relative sense with respect to the tree and ground, since no tree is perfectly straight and vertical, and since the position of a given blind and its support will vary somewhat from one installation to another on different trees.
FIGS. 3 through 5 are top, rear, and bottom views of blind 10 and the section of the tree trunk to which it is fastened. The relationship of the rear wall 18 to the trunk 28 and the field of vision afforded through the rear window 18 a are readily apparent (see FIG. 4 ). The cantilever support's anchor blocks 26 c and 26 d are shown in more detail in FIGS. 3 and 5 , with wide, V-shaped tree-engaging faces 27 for a cradled, self-centering wedge fit against the trunk. In the illustrated embodiment, the anchor blocks are made from wood, providing non-damaging surfaces against the bark of the tree. In the illustrated embodiment the blocks are laminated with multiple layers of engineered lumber locked together into a block with framing members and nails, screws, clamping members and/or strong adhesive. Eyebolts 26 f are secured deeply into the anchor blocks, with hooks or eyes on their protruding ends to receive the ends of chains, cables or straps that can be tensioned around the tree.
In the illustrated example, upper and lower anchor blocks 26 c and 26 d are identical. The wide and relatively shallow nature of the V-shaped anchor block faces 27 , and their rigid vertical spacing on the trunk in a two-point tensioned connection, securely centers and locks the cantilevered mounting structure 26 (and blind 10 ) both vertically and laterally to the side of the tree. It will be understood that the angle and size of the V-shaped tree-engaging faces of the blocks could differ, but identical blocks have been found sufficient.
FIG. 6 illustrates an alternate tree-mounted blind 100 according to the invention, similar to blind 10 in FIGS. 1 through 5 but hexagonal in shape. Like blind 10 it is fully enclosed by its six walls 112 , 113 , 114 , 115 , 116 , 118 and corresponding windows 112 a , 113 a , etc.; its floor 120 ; and its roof 122 . The door 124 is the same as in blind 10 , as are cantilever mount structure 26 and ladder 30 . The hexagonal shape is not only aesthetically pleasing in the visual context of the vertical, generally cylindrical tree, but offers a more finely gradated viewing and shooting field from the interior of the blind, better rear angle views around the tree trunk, and produces a smaller diameter and lighter blind for relatively the same interior comfort and usable space. The hexagonal shape also sheds wind better than a square-sided blind.
The hexagonal blind 100 of FIG. 6 is only one of many possible shapes that can be used for the enclosed blind structure, including but not limited to rectangles, octagons, and even cylinders. It is preferred, however, that the shape chosen have a flat rear wall facing the tree and a flat front wall for a door and ladder opposite the cantilever support on the tree trunk.
The enclosed, tree-paralleling shape of the blind and its cantilever mount to the side of the tree allow the blind to be assembled and installed on the tree in a unique and convenient manner. The blind's walls, floor, and roof portions are preferably constructed as separate modules or sections that are easily transported and that can be quickly assembled using ordinary hand or power tools at the base of a tree, for example by bolting or screwing the sections together. The cantilever support structure 26 is formed as a separate, stand-alone module that is easily transported to the tree, fastened to the base of the tree with its chains in the same manner shown higher up in FIGS. 1–6 , and then used as an off-the-ground platform at a convenient height to assemble and secure the blind to the support structure.
The hexagonal blind 100 shown in FIGS. 6 and 7 lends itself particularly well to a convenient modular assembly that is easy to transport to and from the blind site. As shown in FIG. 7 , the flat rectangular walls 112 – 118 are formed in three hinged sections that fold flat for transport and that open up into freestanding sections to be positioned on and secured to floor 120 . FIGS. 7A and 7B illustrate a preferred folding floor structure adapted to receive the hinged wall sections. Floor 120 has two symmetrical folding halves 120 a and 120 b , hinged along centerline 121 with hinges 120 f on the underside base framing 120 e so as to fold flat. The upper side of floor 120 has a wall-receiving channel 120 c defined about its periphery by raised wooden frame members 120 d . The wall sections are simply dropped into place in channel 120 c and secured to one another and/or the floor, ready to receive roof 122 shown in FIG. 7C . Roof 122 is formed in six triangular sections 122 a with roof anchor cleats 122 b aligned to form a hexagon sized to fit inside the hexagonal walls and be secured thereto with removable fasteners.
FIG. 8 shows the fully assembled blind 100 and support 26 being raised as a unit straight up the side of the tree, for example with a hoist and/or pulley system anchored to the tree, the ground, and/or a vehicle. The wide V-shaped tree-engaging faces on the anchor blocks serve as guides and prevent undue rotation or twisting as the combined blind and support are raised into position. Once in position, the tensioning means secured to the blocks are simply tightened once again around the tree trunk to lock the blind in its final hunting position. The ladder can then be placed at the door of the blind.
It will be understood that the foregoing method for pre-mounting the cantilever support 26 to the tree and assembling the blind on the support at the base of the tree is not limited to hexagonal blind 100 , but can be used for any shape of blind designed for use with support 26 against the side of a tree. For example, square blind 10 in FIGS. 1–5 can be assembled to support 26 in similar fashion. For a blind so assembled to be raised up along the trunk of the tree, however, it should be symmetrical, taller than it is wide, and of relatively small diameter to minimize twisting and swinging.
FIG. 9 illustrates an enclosed, walled blind of a type more likely to be preferred by warmer weather hunters and bowhunters. Blind 200 is open-topped with four windowless walls 212 , 214 , 216 , 218 , a drainable floor 220 , and a door 224 . Blind 200 still provides a fully walled enclosure for the hunter, and is mounted on the same cantilever support structure 26 shown in FIGS. 1–8 for blinds 10 and 100 . Its construction and materials are similar, except for the flooring which preferably allows rain, leaves and snow to fall through, for example by making the floor from expanded metal mesh, strong plastic grating, or wooden slats with spaces between them. Blind 200 can be assembled, raised, secured, and lowered in a manner similar to that described above for blinds 10 and 100 .
It has been found that with the windowed blinds such as 10 and 100 , draping a dull or camouflage colored piece of fine mesh such as mosquito or no-see-um netting over the inside surface of a window as shown at 17 in FIG. 1 effectively renders the hunter and his motion inside the blind invisible from the outside, yet able to see clearly enough to hunt. This mesh or screen also creates a mirror effect when viewed from the outside of the blind, such that the trees and sky are reflected in a non-game-spooking manner, adding to the concealment effect.
It will be understood by those skilled in the art that my invention is subject to various modifications not expressly disclosed in the preferred examples set forth above. Changes in materials, dimensions, and shapes; the specifics of framing, fasteners, and window and door closures; modifications to the cantilever support; and others that will be apparent now that I have explained the invention through these examples will be within the scope of the invention as claimed below. It will also be understood that although the invention is ideally suited and intended for hunting, it may be possible to put it to similar uses such as game and bird watching, for example. I accordingly claim: | An enclosed tree-mounted hunting blind supported in cantilever fashion off the side of a tree. The blind is a rigid, walled structure that is easily put up and taken down from the tree using its own cantilever support, and is light enough to transport to and from the tree at the beginning and end of hunting season with minimal effort. The assembled, tree-mounted blind, however, is as stable as a permanently mounted structure and offers the protection and comfort of a ground blind in a tree. | 8 |
FIELD OF THE INVENTION
The present invention relates to a reactive dyestuff, especially relates to a novel blue reactive dyestuffs.
SUMMARY OF THE INVENTION
The present invention provides the blue reactive dyestuffs of the following formula (I): ##STR2## wherein: R 1 and R 2 each independent is hydrogen, halogen, C 1-4 alkyl, C 1-4 alkoxyl, or sulfonyl groups;
X is halogen or quaternary ammonium, and it is preferred that X is fluorine or chlorine;
X 1 and X 2 each independent is hydroxyl or amino; it is preferred that X 1 is hydroxyl and X 2 is amino, or X 1 is amino and X 2 is hydroxyl;
Y is --SO 2 CH 2 ═CH 2 or --SO 2 C 2 H 4 W, W is a leaving group (e.g. halogen, acetyl, phosphate, trisufate, and sulfate; wherein sulfate is preferably) which is eliminable by a base;
Z is --CHTCH 2 T or --CT═CH 2 , T is halogen, --OH, --OSO 3 H, or a leaving group which is eliminable by a base; and it is preferred that T is chlorine or bromine.
The present invention provides the blue reactive dyestuffs with multiple reactive groups. The dyestuffs of the present invention have the characteristics of high color fastness and high exhaustion rate, when dyeing the cellulose fibers. Additionally, these kinds of dyestuffs are stable in the storage, the bonding stability between dye and fiber is very high, and the color reproducibility effect is getting better after dyeing. Due to the high fastness of colors, the dye residue in the waste water can be reduced. The high use percentage of dye means reduction of cost, and the environmental problems from the waste water can be reduced or even eliminated. Consequently, multiple reactive groups are introduced to the main body of the dye, which may result in the characteristics of high color fastness and high exhaustion rate when dyeing the cellulose fibers. Furthermore, the color reproducibility is getting better, and the high fastness can be obtained.
These kinds of dyestuffs are suitable for dyeing and printing of materials containing either cellulose fibers, such as cotton, synthetic cotton, hemp, and synthetic hemp, or synthetic polyamide and polyurethane fibers, such as wool, silk, and nylon. The dyestuffs are also suitable for dyeing and printing of cellulose fibers, polyamide fibers, polyurethane fibers, polyacrylic fibers and other blends. Materials of high degree dye fastness can be obtained.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The blue reactive dyestuffs of formula (I) of the present invention can be synthesized by the following method A or method B.
Method A:
First of all, a diazonium salt of the following formula (1) ##STR3## wherein R 1 , R 2 , and Y are defined as the above, is coupled with 1-amino-8-hydroxyl naphthalene-3,6-disulfonic acid. Examples of suitable formula (1) are: ##STR4## The temperature of the coupling reaction is controlled between 0 to 40° C., and below 30° C. is preferred. The pH is controlled between 1 to 3, and below 2 is preferred. Upon completion of the coupling reaction, the compound of the following formula (2) ##STR5## Wherein R 1 , R 2 , and Y are defined as the above, can be obtained. Then 2,4-diamino benzene sulfonic acid and trihalogentriazine are condensed to obtain the compound of the following formula (3), wherein X is defined as the above. ##STR6## Then the diazonium salt of the formula (3) is coupled with the compound of the above formula (2). The reactive temperature is controlled between 0 to 40° C., and below 30° C. is preferred. The pH is controlled between 6 to 7, and 6.0 to 6.5 is preferred. Upon completion of the coupling reaction, the compound of the following formula (4) ##STR7## wherein R 1 , R 2 , X, and Y are defined as the above, can be obtained. Examples of the formula (4) are: ##STR8## 2,4-Diamino benzene sulfonic acid is condensed with the compound of the following formula (5), ##STR9## wherein Z is defined as the above. The reactive temperature is controlled between 0 to 25° C., and 0 to 10° C. is preferred. The pH is controlled between 2 to 7, and 5 to 7 is preferred. Then the compound of the following formula (6) ##STR10## wherein Z is defined as the above, can be obtained.
The compound of the formula (6) is condensed with the compound of formula (4). The reactive temperature is controlled between 0 to 40° C., and below 30° C. is preferred. The acid generated in the reaction is then neutralized by adding the acid-binding agent, and the pH is controlled between 4 to 7, and 4.5 to 6.5 is preferred. After fully stirred, the compound of the following formula (I') ##STR11## wherein R 1 , R 2 , X, Y and Z are defined as the above, can be obtained. The compound of the formula (I') is one of the blue reactive dyestuffs of the present invention.
Method B:
The diazonium salt of the formula (3) is coupled with 1-amino-8-hydroxyl naphthalene-3,6-disulfonic acid. The coupling reaction temperature is controlled between 0 to 40° C., and below 30° C. is preferred. The pH is controlled between 1 to 3, and below 2 is preferred. Upon completion of the coupling reaction, the compound of the following formula (7) can be obtained. ##STR12##
The diazonium salt of the above formula (1) is coupled with the compound of the formula (7). The reactive temperature is controlled between 0° C. to 40° C., and below 30° C. is preferred. The pH is controlled between 6 to 7, and 6.0 to 6.5 is preferred. Then the compound of the following formula (8) ##STR13## wherein R 1 , R 2 , X, and Y are defined as the above, can be obtained. Examples of the formula (8) are: ##STR14##
The compound of the formula (8) is condensed with the compound of the above formula (6), and the compound of the following formula (I") ##STR15## wherein R 1 , R 2 , X, Y, and Z are defined as the above, can be obtained. The compound of the formula (I") is one of the blue reactive dyestuffs of the present invention.
In the manufacture process, the suitable acid-binding agents are alkali metal hydroxides, alkali metal carbonates, or alkali metal bicarbonates. The hydroxides, carbonates, or bicarbonates of sodium, potassium, or lithium are preferably, and particularly sodium carbonates or bicarbonates are most preferably.
The dyestuffs of the present invention can be produced by the above methods, and the reactive conditions were fully described in the above explanation. Similarly, the dyestuffs can be purified by known processes such as spray drying, precipitation, or filtration.
The dyestuffs of the present invention can be in the form of powder, granular, particle or liquid and an auxiliary reagent, for example, retarding agent, leveling agent, assistant agent, surfactant agent, or dispersing agent may be added.
The dyestuffs of the present invention all contain anion group, such as sulfonyl group. For convenience in statement, they are expressed as free acid in the specification. When the dyestuff of present invention is manufactured, purified or used, it often exist in the form of water soluble salt, especially the alkaline metallic salt, such as sodium salt, potassium salt or ammonium salt.
More detailed examples are used to illustrate the present invention, and these examples are used to explain the present invention. The examples below, which are given simply by way of illustration, must not be taken to limit the scope of the invention.
In examples, the compound is represented by free acid, but its actual form can be metallic salt, or more possibly alkali salt, especially sodium salt.
EXAMPLE 1
Trichlorotriazine (5.5 g) was first uniformly distributed in ice water(50 ml), then a solution of 2,4-diamino benzene sulfonic acid (5.6 g) in 150 ml of water was added. The mixture was then stirred for half hour and the pH was controlled between 6.0 to 6.5 for the full reaction. Then the resultant mixture was formed the diazonium salt solution (A) by known methods.
Add diazonium salt of 4-((2-(sulfooxy) ethyl) sulfonyl) phenylamine (prepared from 8.4 g 4-((2-(sulfooxy) ethyl) sulfonyl) phenylamine ) into a solution of 1-amino-8-hydroxyl naphthalene-3,6-disulfonic acid (9.6 g) in 100 ml of water. Sodium bicarbonate was used to control the pH between 1.0 to 3.0, and the mixture was stirred until full reaction. Then the mixture was added into the above solution (A) and stirred at a pH of 6.0-6.5 until fully reacted. Then a solution of 2,4-diamino benzene sulfonic acid (5.6 g) in 100 ml of water was added. The pH was controlled between 5.5 to 6.0 and temperature was controlled at 30° C. The solution was stirred until full reaction. Then the solution temperature was controlled at 5° C. and 2,3-dibromo propanoyl chloride (7.5 g) was added. The solution was stirred until full reaction, and the dyestuff of the following formula (I-1) could be obtained. After salting, drying and grinding, a blue dye powder could be obtained. The dyestuff can be used to dye objects in blue, with excellent property. ##STR16##
EXAMPLE 2
Refer to the procedure of example 1, substitute 4-((2-(sulfooxy) ethyl) sulfonyl) phenylamine with 2-amino-5((2-(sulfooxy) ethyl) sulfonyl) benzene sulfonic acid to obtain blue dyestuff of formula (I-2). After salting, drying and grinding, a blue dye powder could be obtained. The dyestuff can be used to dye objects in blue, with excellent property. ##STR17##
EXAMPLE 3
Refer to the procedure of example 1, substitute 4-((2-(sulfooxy) ethyl) sulfonyl) phenylamine with 2-amino-5-(vinyl sulfonyl) benzene sulfonic acid to obtain blue dyestuff of formula (I-3). After salting, drying and grinding, a blue dye powder could be obtained. The dyestuff can be used to dye objects in blue, with excellent property. ##STR18##
EXAMPLE 4
Trichlorotriazine (5.5 g) was first uniformly distributed in ice water(50 ml), then a solution of 2,4-diamino benzene sulfonic acid (3.4 g) in 150 ml of water was added. The mixture was then stirred for half hour and the pH was controlled between 6.0 to 6.5. Then the resultant mixture was formed the diazonium salt solution by known methods. A solution of 1-amino-8-hydroxyl naphthalene-3,6-disulfonic acid(9.6 g)in 100 ml of water was added. The pH of mixture was controlled below 3.0 and the temperature was controlled at 5° C. The mixture solution was stirred until full reaction. Then a solution of 4-((2-(sulfooxy) ethyl) sulfonyl) phenylamine (8.4 g) in 50 ml of water was added and stirred at a pH between 6.0 to 6.5 until fully reacted. Then a solution of 2,4-diamino benzene sulfonic acid (5.6 g) in 100 ml of water was added and stirred at a pH between 5.5 to 6.0 and temperature at 30° C. until fully reacted. Then 2,3-dibromo propanoyl chloride (7.5 g) was added and the pH was controlled between 4.5 to 6.5 and the temperature was controlled between 0 to 5° C. The solution was stirred until full reaction, then the dyestuff of the following formula (I-4) could be obtained. After salting, drying and grinding, a blue dye powder could be obtained. The dyestuff can be used to dye objects in blue, with excellent property. ##STR19##
EXAMPLE 5
Refer to the procedure of example 4, substitute 4-((2-(sulfooxy) ethyl) sulfonyl) phenylamine With 4-(vinyl sulfonyl)-5-methyl-2-methoxy phenylamine, to obtain blue dyestuff of formula (I-5). After salting, drying and grinding, a blue dye powder could be obtained. The dyestuff can be used to dye objects in blue, with excellent property. ##STR20##
EXAMPLE 6
Refer to the procedure of example 4, substitute 4-((2-(sulfooxy) ethyl) sulfonyl) phenylamine With 4-(vinyl sulfonyl)-2-methoxy phenylamine, to obtain blue dyestuff of formula (I-6). After salting, drying and grinding, a blue dye powder could be obtained. The dyestuff can be used to dye objects in blue, with excellent property. ##STR21##
EXAMPLE 7
The dyestuff of formula (I-1) was dissolved in 100 ml of water and sodium hydroxide solution was added to control the pH between 12-12.5. The mixture was stirred at the temperature of 0 to 5° C. until full reaction. Then hydrochloric acid solution was added to control the pH at 7.0 and the dyestuff of formula (I-7) was obtained. After salting, drying and grinding, a blue dye powder could be obtained. The dyestuff can be used to dye objects in blue, with excellent property. ##STR22##
EXAMPLE 8-12
Refer to the procedure of example 7, substitute (I-1) With (I-2), (I-3), (I-4), (I-5), and (I-6), to obtain blue dyestuffs of formula (I-7), (I-8), (I-9), (I-10), (I-11), and (I-12). The structure of the formula (I-8) is the same as that of the formula (I-9). These dyestuffs can be used to dye objects in blue, with excellent property. ##STR23##
EXAMPLE 13
Diazonium salt of 4-((2-(sulfooxy) ethyl) sulfonyl) phenylamine (prepared from 8.4 g 4-((2-(sulfooxy) ethyl) sulfonyl) phenylamine) was added into a solution of 1-amino-8-hydroxyl naphthalene-3,6-disulfonic acid (9.6 g) in 100 ml of water. Sodium bicarbonate was used to control the pH between 1.0 to 3.0, and the mixture was stirred until full reaction to obtain solution (13A).
Trichlorotriazine (5.5 g) was first uniformly distributed in ice water (50 ml), then a solution of 2,4-diamino benzene sulfonic acid (5.6 g) in 150 ml of water was added. The mixture was then stirred for half hour and the pH was controlled between 6.0 to 6.5 for the full reaction. Then the resultant mixture was formed the diazonium salt solution by known methods. The diazonium salt solution was added to the above solution (13A) and stirred at a pH of 6.0-6.5 until fully reacted. Then a solution of 2,4-diamino benzene sulfonic acid (5.6 g) in 100 ml of water was added. The pH was controlled between 5.5 to 6.0 and temperature was controlled at 30° C. The solution was stirred until full reaction. Then the solution temperature was controlled at 5° C. and 2,3-dibromo propanoyl chloride (7.5 g) was added. The solution was stirred until full reaction, and the dyestuff of the following formula (I-13) could be obtained. After salting, drying and grinding, a blue dye powder could be obtained. The dyestuff can be used to dye objects in blue, with excellent property. ##STR24##
EXAMPLE 14
Trichlorotriazine (5.5 g) was first uniformly distributed in ice water(50 ml), then a solution of 2,4-diamino benzene sulfonic acid (5.6 g) in 150 ml of water was added. The mixture was then stirred for half hour and the pH was controlled between 6.0 to 6.5 for the full reaction. Then the resultant mixture was formed the diazonium salt solution (14A) by known coupling reaction methods.
Diazonium salt of 2-amino-5-((2-(sulfooxy) ethyl) sulfonyl) benzene sulfonic acid (prepared from 13.91 g 2-amino-5-((2-(sulfooxy) ethyl) sulfonyl) benzene sulfonic acid was added into a solution of 1-amino-8-hydroxyl naphthalene-3,6-disulfonic acid (9.6 g) in 100 ml of water. Sodium bicarbonate was used to control the pH between 1.0 to 3.0, and the mixture was stirred until full reaction. Then the above solution (14A) was added into the above mixture. The resultant mixture was controlled at the pH between 6.0-6.5 and was stirred until full reaction to obtain the solution (14B).
2,3-dibromo propanoyl chloride (7.5 g) was added into a solution of 2,4-diamino benzene sulfonic acid (5.6 g) in 100 ml of water to form the solution (14C). Then the solution (14B) was added into the solution (14C). The pH was controlled between 5.5 to 6.0 and temperature was controlled at 30° C. The solution was stirred until full reaction, and the dyestuff of the following formula (I-14) could be obtained. After salting, drying and grinding, a blue dye powder could be obtained. The dyestuff can be used to dye objects in blue, with excellent property. ##STR25##
EXAMPLE 15
Trichlorotriazine (5.5 g) was first uniformly distributed in ice water(50 ml), then a solution of 2,4-diamino benzene sulfonic acid (5.6 g) in 150 ml of water was added. The mixture was then stirred for half hour and the pH was controlled between 6.0 to 6.5 for the full reaction. Then the resultant mixture was formed the diazonium salt solution (15A) by known methods. a solution of 1-amino-8-hydroxyl naphthalene-3,6-disulfonic acid (9.6 g) in 100 ml of water was added into the solution (15A). The mixture was stirred at the pH below 3.0 ant the temperature at 5° C. until full reaction. Then a diazonium salt of 2-amino-5-((2-(sulfooxy) ethyl) sulfonyl) benzene sulfonic acid (13.91 g) in 50 ml of water was added. The resultant mixture was controlled at the pH between 6.0-6.5 and was stirred until full reaction to form the solution (15B).
2,3-dibromo propanoyl chloride (7.5 g) was added into a solution of 2,4-diamino benzene sulfonic acid (5.6 g) in 100 ml of water to form the solution (15C).
Then the solution (15B) was added into the solution (15C). The pH was controlled between 5.5 to 6.0 and temperature was controlled at 30° C. The solution was stirred until full reaction, and the dyestuff of the following formula (I-15) could be obtained. After salting, drying and grinding, a blue dye powder could be obtained. The dyestuff can be used to dye objects in blue, with excellent property. ##STR26##
EXAMPLE 16-18
Refer to the procedure of example 7, substitute (I-1) With (I-13), (I-14), and (I-15), to obtain blue dyestuffs of formula (I-16), (I-17), and (I-18). These dyestuffs can be used to dye objects in blue, with excellent property. ##STR27##
From the foregoing description, one skilled in the art can easily ascertain the essential characteristics of this invention, and without departing from the scope thereof, can make various changes and modifications of the invention to adapt it to various usages and conditions. Thus, other embodiments are also within the claims. | The present invention provides the blue dyestuffs of the following formula (I), ##STR1## wherein R 1 , R 2 , X, X 1 , X 2 , Y, and Z are defined in this document. These kinds of dyestuffs are suitable for dyeing and printing of materials containing either cellulose fibers, such as cotton, synthetic cotton, hemp, and synthetic hemp, or synthetic polyamide and polyurethane fibers, such as wool, silk, and nylon. | 2 |
1. RELATED APPLICATIONS
The present application claims the benefit of U.S. Provisional Patent Application 60/581,051, filed Jun. 17, 2004.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to improved bullet targets. More specifically, the present invention relates to modular targets which improve the function of the target to improve shooter abilities and to decrease broken targets.
2. State of the Art
In order to maintain proficiency in the use of firearms, it is common for law enforcement officers and sportsmen to engage in target practice. Target practice is both enjoyable to the individual and valuable training to increase the individual's skills and efficiency with a firearm. Accordingly, target practice increases the ability of an individual to use a firearm safely and effectively.
The use of shooting ranges for target practice provides a level of training which is difficult to duplicate in other types of target practice. Shooting ranges can provide multiple targets, moving targets, and other stimulus which may increase the effectiveness of the target practice in training the individual.
While target practice in a shooting range is advantageous, it is not always available to an individual desiring target practice. Accordingly, there is a need for portable shooting targets which allow an individual to achieve adequate practice with his or her firearm.
Portable targets have been used for some time. Many of these targets are limited in use. Because of the design of the targets, some targets may only be used where there is soft dirt into which stakes or metal poles which may be attached to the target may be inserted. Such targets can not be used where the ground is too hard to allow insertion of the stakes or poles. Likewise, they can not be used on asphalt or concrete.
Additionally, such targets may become loosened with use, as the impact of projectiles hitting the target moves the target and loosens the stakes or poles from the ground into which they are inserted. A target which becomes loose during use may become unsafe and ineffective to use for target practice.
Additionally, some targets are not suitable for use with larger firearms. Many targets are constructed by welding metal plates together, by bending or twisting metal plates, by using nuts or bolts to hold pieces of the target together, or by using hinges or other attachment mechanisms. Such construction methods are prone to failure with repeated use. The heat involved with welding metal may weaken the metal surrounding the joint. Additionally, welds tend to be brittle as compared to the metal itself, and welds are more prone to failure than plain metal plate. Additionally, welding increases the time and cost necessary to produce a target. Similarly, bending or twisting metal may make the metal more brittle and more prone to failure. The additional steps and machinery necessary to bend or twist the metal increase the cost to manufacture the target.
The use of bolts and hinges to manufacture targets is also disadvantageous, as the nuts, bolts, or hinges may be loosened or destroyed with use. The vibration of projectiles repeatedly hitting the target will typically loosen the nuts, bolts, or hinges. Loose joints on a target will make the target less functional and unsafe. Additionally, projectiles directly hitting the nuts, bolts, or hinges of a target may destroy the nuts, bolts, or hinges. For some bullets, a single bullet or a few bullets may destroy a nut, bolt, or hinge when striking it directly.
Some targets are simply made too thin or too weak to be useful as a target for larger firearms. The metal used for constructing the target may be too soft because of manufacturing constraints such as cutting, bending, or shaping, cost limitations, etc. For example, a twisted piece of metal for use as a target must usually be mild steel rather than hardened steel. Other targets are too expensive for many individuals.
Thus, there is a need for simple bullet targets which provide improved functionality for training and with improved wear characteristics.
SUMMARY OF THE INVENTION
It is the object of the present invention to provide improvements in bullet targets.
In accordance with the above and other objects of the invention, an improved bullet target is provided, including a shooting plate which is configured to be impacted by a bullet, a frame for holding the shooting plate in a line of fire, and a foot or multiple feet for holding the frame in a generally vertical position.
In accordance with one aspect of the invention, the attachment mechanism is formed by an protrusion of metal from the shooting plate. The metal protrusion attaches the shooting plate to the frame in such a manner that the shooting plate will pivot and deflect each time it is hit, but will substantially return to its initial position (generally vertical) shortly after the impact. Thus, the shooting plate gives the visual appearance of being impacted as it is hit with each bullet to confirm to the shooter that he or she has hit the target. Because no hinge is directly formed on the shooting plate, the shooting plate is able to withstand a larger number of rounds without any damage to the pivoting mechanism.
In accordance with another aspect of the invention, the frame may be formed from a flat strip of steel which is bent so as to have a generally horizontal portion and two generally vertical portions. The horizontal portion is designed to be parallel with the ground, and the generally vertical portions are configured to support the shooting plate. Accordingly, the vertical portions may have holes formed in their upper ends which may receive the metal protrusions formed in the shooting plate.
In accordance with yet another aspect of the invention, the foot or feet are configured to attach to the lower portion of the frame, near or attached to the generally horizontal portion. The foot or feet are configured to extend forward and backward from the frame sufficiently to support the target and prevent the target from falling over when struck from projectiles from a firearm, bumped, confronted with wind, or other common interactions. The feet are also preferably configured to engage the frame so that the frame does not encounter a significant of splatter from bullets ricocheting off the target.
In accordance with another aspect of the present invention, the target may be configured such that multiple targets may be used in combination. The targets may be configured such that multiple targets may be attached together.
In accordance with still another aspect of the invention, the target shooting plate can be configured to present different shapes or colors or targets to the individual desiring target practice.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other objects, features and advantages of the invention will become apparent from a consideration of the following detailed description presented in connection with the accompanying drawings in which:
FIGS. 1 and 1A show front and side views of a target known in the prior art;
FIG. 2 shows a front perspective view of an improved target made in accordance with the principles of the present invention;
FIG. 3 shows a side perspective view of an improved target made in accordance with the principles of the present invention;
FIG. 4 shows a disassembled view of the individual pieces of an improved target made in accordance with the principles of the present invention; and
FIG. 5 shows a perspective view of multiple targets used together in accordance with the principles of the present invention.
DETAILED DESCRIPTION
Reference will now be made to the drawings in which the various elements of the present invention will be given numeral designations and in which the invention will be discussed so as to enable one skilled in the art to make and use the invention. It is to be understood that the following description is only exemplary of the principles of the present invention, and should not be viewed as narrowing the pending claims.
Turning now to FIGS. 1 and 1A , there is shown front and side views of a target known to the prior art, generally indicated at 10 . The target includes a target plate 12 and a support piece 14 , which is used to hold the target plate 12 in a line of fire. The support piece 14 further comprises a cross member 16 . The cross member 16 is typically welded to the support piece 14 . The support piece 14 is typically configured to have two pointed ends 18 a and 18 b . The pointed ends 18 a and 18 b are configured to be inserted into the ground. The cross member 16 may be configured to provide a place whereon the user may step to aid in pressing the ends 18 a and 18 b of the support piece 14 into the ground.
The weld joint between the support piece 14 and the cross member 16 creates a weak portion of the target support. During repeat fire situations, the weld can break due to the vibration of repeated rounds hitting the target plate or from direct hits to the welds by errant shots. This can eventually cause the cross member 16 to fall off of the support piece 14 , or otherwise interfere with the structural integrity of the target and the ability of the user to step on the cross member 16 to drive the pointed ends 18 a and 18 b into the ground.
The support piece 14 is typically formed from round steel rod which is bent into the shape shown. The cross member 16 is also typically formed from round steel rod. The support piece 14 acts as a pivot for the target plate 12 . The target plate 12 is usually formed with a hole 20 , as shown in view of side 12 a , through which the support piece 14 passes. The hole 20 is sized such that the target plate 12 pivots freely about the support piece 14 .
The target plate 12 is typically formed from plate steel, and is typically twisted 26 at the intersection between the central portion 22 and the rounded end portions 24 a and 24 b . The twist 26 reduces the strength in the target as it creates a weaker location in the steel. Additionally the target plate 12 must be made of mild steel plate which allows twisting. Having a target portion which is twisted and formed of mild steel makes the target portion less durable and more prone to failure.
Targets which are formed from welded steel, or which have designs which incorporate twists, bends, or hinges, especially on the target plate or in close proximity, are more prone to failure because of how these construction methods weaken the steel or require softer steel to be used.
Additionally, the target 10 as known in the prior art must be used in an area with dirt which is sufficiently soft to allow the user to press the ends 18 a and 18 b of the support piece 14 into the dirt. This limits the number of areas where the target may be used. Additionally, dirt which is soft enough to allow use of the target 10 may not be hard enough to maintain the target firmly planted in the ground during a target shooting session. The holes formed in the dirt may become enlarged due to the vibrations and forces exerted on the target from the bullets striking the target. If the holes become enlarged, the target will be loosely held in the dirt, and could move with the impacts of successive bullets striking the target. This reduces the safety and effectiveness of the target.
Turning now to FIG. 2 , a front perspective view of a target (indicated generally at 40 ) made in accordance with the present invention is shown. The target 40 comprises a shooting plate 42 , a frame 44 , and feet 46 .
The shooting plate 42 is formed from a single piece of flat steel, preferably hardened steel plate. The shooting plate 42 is typically configured to have a cross piece 42 a , two target plates 42 b and 42 c , and two mounting protrusions 42 d . Because the entire shooting plate 42 is constructed out of a single flat plate of steel, no bending, twisting, welding, etc. is required. The absence of bends or twists allows the shooting plate 42 to be constructed out of a harder steel as compared to a steel which readily allows for bending or twisting during manufacture. The harder steel and absence of bends, twists, or welds makes the shooting plate 42 stronger and less prone to failure. As discussed previously, welds, bends, or twists are prone to break from the stresses and vibrations caused by the repeated impact of bullets.
The protrusions 42 d are designed to fit rotatably in corresponding holes ( 50 in FIG. 3 ) in the frame 44 . This allows the shooting plate 42 to rotate freely when struck by a bullet. (It will be appreciated that the entire cross piece could be sized similar to the protrusions if desired.
The shooting plate 42 is typically designed to have two target plates 42 b and 42 c . These target plates may be a variety of shapes, such as circular, oval, rectangular, square, triangular, or polygonal, and may also be shaped to resemble animals, birds, rodents, rabbits, snakes, deer, or anything else that an individual might commonly shoot at. The two target plates 42 b and 42 c may also be made of different sizes. One will appreciate that the larger, and consequently heavier, of the two target plates 42 b and 42 c will naturally hang below the cross piece 42 a.
The target plates 42 b and 42 c may also be painted or otherwise finished to be different in color. This may be done so as to make the target more accurately resemble the item depicted in the target plate. Colors may also be selected for training purposes, such that the individual shooting at the target is required to shoot targets based on color.
The target 40 may also be designed such that different shooting plates 42 may be used, depending on the training desired. A user could select a shooting plate based on the shape or color of the target plates 42 b and 42 c , and place the desired shooting plate 42 into the frame 44 . The upper ends of the frame could be stretched apart just far enough to allow the protrusions 42 d of the shooting plate 42 to be removed from the holes ( 50 in FIG. 3 ), and for a different shooting plate to be similarly inserted into the frame 44 .
The target 40 is also typically configured to have a foot or multiple feet 46 . The embodiment shown is configured to have two feet 46 , which attach to the lower portion of the frame 44 . The foot or feet 46 are typically designed to extend forwards and backwards from the target 40 to adequately support the target 40 . The feet 46 are designed such that the target 40 will not fall over during any occurrence which will commonly occur while an individual is engaged in target practice.
Turning now to FIG. 3 , a side perspective view of the target of FIG. 2 , indicated generally at 40 , and made in accordance with the present invention is shown. The target 40 comprises a shooting plate 42 , a frame 44 , and feet 46 . FIG. 3 more clearly shows the holes 50 formed in both sides of the frame 44 and configured to receive the protrusions ( 42 d of FIG. 2 ) of the shooting plate 42 . Also visible in FIG. 3 are connecting holes 52 which may be formed in the sides of frame 44 . The connecting holes 52 may be used to connect multiple targets 40 together, as will be discussed.
The feet 46 are shown to extend forwards and backwards from the frame 44 . The feet 46 may extend further backwards from the frame 44 to prevent the target 40 from falling backwards from the impact of bullets striking the target.
One important aspect of the feet 46 is that they engage the frame 44 so that the frame is held at an angle less than vertical. In such a manner, bullet fragments ricocheting off the shooting plate 42 are more likely to impact the ground than the frame 44 . This reduces wear on the frame and provides improved longevity. For example, if a shooter shoots toward the shooting plate from the left, bullets fragments will ricochet off the plate downwardly and outwardly prior to impacting the frame 44 .
Turning now to FIG. 4 , multiple views of the individual pieces of the target are shown. The feet 46 may be configured to have downwardly extending protrusions 60 to allow the feet 46 to rest more securely on ground which may be uneven. The feet 46 may also be formed with a slot 62 . The slot 62 is typically configured to allow insertion of the frame 44 into the slot 62 , allowing the feet 46 to be slid onto the lower portion of the frame 44 a . The frame may have protrusions 64 against which the feet may rest when installed on the frame 44 . The protrusions prevent the feet from sliding too far inwardly on the frame 44 , making the target unstable.
The frame 44 may also have holes 66 on the lower portion 44 a of the frame 44 . Bolts can be placed through the holes 66 after the feet have been installed to prevent the feet 46 from sliding outwardly on the frame. Conversely, long spikes 68 may be inserted downwardly through the holes 66 after the feet 46 have been installed. The spikes 68 will prevent the feet from sliding outwardly on the frame 44 , and also are long enough to extend downwardly into the ground and prevent the target from sliding.
The embodiment of the target shown is thus advantageous in that it may be used both on dirt, or more solid surfaces which do not readily allow for insertion of a spike to secure a target. On a hard surface, the feet 46 may be installed without spikes 68 . The target will then rest on the surface. The feet 46 are sufficiently large to prevent the target from falling, and may be designed to also prevent the target from sliding if configured to have some relatively sharp points or corners on the bottom of the feet 46 or the protrusions 60 on the feet 46 . The same target, if used on softer ground, may be securely attached to the ground by inserting spikes 68 through the holes 66 in the lower portion of the frame 44 a.
The frame 44 is typically constructed from flat plate steel with two bends 70 to shape the frame into a U shape. It is advantageous to construct the frame 44 from bent plate steel as compared to welded steel, as the bends will be less prone to failure that welds. Additionally, the bends 70 are placed at a reasonable distance away from the shooting plate 42 . This lessens the impact of the vibrations and stresses on the bends 70 resulting from the bullets striking the shooting plate 42 . The design is particularly advantageous because the entire shooting plate 42 is constructed from a single piece of plate steel. Also shown in FIG. 4 are the holes 52 in the frame 44 which may be used to attach multiple targets together.
The shooting plate 42 is shown with target plates 42 b and 42 c of different sizes. Round target plates 42 b and 42 c are shown, but it will be appreciated that many shapes may be used.
Turning now to FIG. 5 , a perspective view is shown of two targets, indicated generally at 80 and 82 , used in combination. Individuals may desire to use multiple targets in combination to provide different training options. For example, the shooting plates 84 a and 84 b may be selected such that the target plates 86 a–d present a variety of shapes and colors to the individual using the targets 80 and 82 for target practice. Using target plates 86 a–d which are of different shapes or colors, a trainer may call out or otherwise signal various shapes or colors and require the shooter to quickly identify the corresponding target and shoot appropriately.
When multiple targets 80 and 82 are used in combination, the user may desire to attach the targets together with bolts 88 and nuts 90 . The user may also use a spacer 92 place between the targets 80 and 82 to maintain a proper distance between the targets 80 and 82 so as to allow the shooting plates 84 a and 84 b to move freely. Attaching the targets 80 and 82 together with bolts 88 and nuts 90 allows the user to more easily fix the arrangement of the targets 80 and 82 relative to one another, provides some added measure of stability to the targets 80 and 82 , and limits the number of feet needed to stabilize the target.
Although the bolts 88 and nuts 90 are exposed to stray bullets which might hit the bolts 88 or nuts 90 instead of the target plates 86 a–d , the bolts 88 and nuts 90 are not an important structural part of the targets 80 and 82 , as both of the targets 80 and 82 are designed as separate, stand-alone targets and do not rely on the bolts 88 or nuts 90 for structural integrity. If the bolts 88 or nuts 90 are hit and damaged by a few stray bullets, they may simply be replaced when the user disassembles and reassembles the targets 80 and 82 for use in combination. Because the targets 80 and 82 are portable, it is anticipated that the targets 80 and 82 , if used in combination, will be bolted together when set up for a day of target practice and unbolted when taken down for the day. If the user desires to again use the targets 80 and 82 in combination for a different target practice session, the user will be able to easily determine if the bolts 88 or nuts 90 have been damaged, and be able to replace damaged bolts 88 or nuts 90 when setting up the targets 80 and 82 .
One significant advantage of the present invention is that the entire target can be cut from a single piece of hardened plate steel. A piece of plate steel can be placed on a cutting table and an automated cutting torch or other cutting device can cut out each of the pieces. The only handling necessary it to make two quick bends in the frame and the target is ready for shipping.
Thus, there is disclosed an improved target. Those skilled in the art will appreciate that numerous modifications can be made with out departing from the scope of the invention. The appended claims are intended to cover such modifications. | A portable bullet target configured to improve the skills of a shooter includes, in one embodiment, a shooting plate which is attached to a frame by protrusions integral to the shooting plate to allow the shooting plate to visually deflect when hit by a bullet and to substantially return to its original position. In another embodiment, a foot or feet are attached to the frame to support the target. According to another embodiment, a plurality of portable targets are used in combination and may be attached together. | 5 |
This application claims the benefit of U.S. Provisional Application No. 60/881,341, filed Jan. 19, 2007.
FIELD OF THE INVENTION
The present invention relates to bracket assemblies which are used in the front end of an automobile; more particularly, the present invention relates to a bracket member which is used for controlling the relative positioning between a headlamp assembly, the front fascia or top cap, and a fender in an automobile.
BACKGROUND OF THE INVENTION
Fascias or top caps, as well as fenders and headlamps, are generally known and used throughout various types of automobiles. The fascia or top cap is a portion of the body which is typically positioned near, or below the headlights and grille, and is used for providing an aesthetically pleasing appearance. Fenders are a portion of the body which are adjacent to the fascia or top cap, and surrounds the wheel well. These fascias, top caps, and fenders are typically made of a composite material which can be difficult to dimension, as well as position relative to the headlights and one another such that the correct dimensions are achieved.
Often during assembly, due to tolerances and other manufacturing causes, the position of the headlight relative to the fascia (or top cap) or the fender is too large, leaving a gap between the headlight and the fascia or top cap, which detracts from the appearance of the automobile. It is desired to have a minimal gap between the headlight and front fascia or top cap, as well as the fascia and front fender of the automobile.
Accordingly, there exists a need for an improved way of controlling the dimensions between the headlight and the front fascia or top cap, and control the dimensions between the fender and front fascia or top cap.
SUMMARY OF THE INVENTION
The present invention is a component for providing alignment between at least two external components. The present invention is a bracket member having at least two attachment structures, and at least two externally visible components connected to the at least two attachment structures, and the at least two attachment structures provide adjustable positioning between the at least two externally visible components connected to the at least two attachment structures such that the position off the at least two externally visible components can be adjusted relative to one another.
Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein:
FIG. 1 is a perspective rear view of a bracket member, according to the present invention;
FIG. 2 is a first perspective rear view of a bracket member, according to the present invention;
FIG. 3 is a second perspective rear view of a bracket member, according to the present invention;
FIG. 4 is a rear view of a bracket member, according to the present invention;
FIG. 5 is a perspective view of a front end assembly support system for a top cap with the headlamp removed, according to the present invention;
FIG. 6 is an enlarged front view of a bracket member attached to a headlamp support, according to the present invention;
FIG. 7 is a rear perspective view of a fender bracket used with a bracket member, according to the present invention;
FIG. 8 is an enlarged bottom perspective view of a fender bracket and a bracket member, according to the present invention;
FIG. 9 is a second enlarged perspective view of a fender bracket and a bracket member with the headlamp attached, according to the present invention;
FIG. 10 is a perspective front view of a bracket member used in with the fender and top cap attached, according to the present invention;
FIG. 11 is an enlarged perspective view of a bracket member with the headlamp attached, according to the present invention;
FIG. 12 is an enlarged rear perspective rear view of a bracket member for a fender and a top cap, according to the present invention;
FIG. 13 is a side perspective view of a bracket member for a top cap with the headlamp attached, according to the present invention; and
FIG. 14 is a perspective top view of a bracket member with the top cap and fender attached, according to the present invention;
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The following description of the preferred embodiment(s) is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses.
Referring to the Figures generally, a bracket member used for providing proper alignment between a series of externally visible components is shown generally at 10 . The bracket member 10 includes a fascia attachment 12 having a first attachment structure, or U-bracket 14 . The U-bracket 14 includes two flange portions 16 , 18 separated by a gap 20 . The U-bracket 14 connects to more than one externally visible component, such as a fender 22 or a fascia 24 . The U-bracket 14 is also used to provide support for the fender 22 and fascia 24 as well. The fender 22 includes a flange 26 , and the fascia 24 also includes a flange 28 ; both the flanges 26 , 28 are received in between the flange portions of the U-bracket 14 . The fascia attachment 12 has a main aperture 30 which extends through both flange portions 16 , 18 of the U-bracket 14 and aligns with a first aperture 32 on the fascia 24 , a second aperture 34 on the fender 22 .
Connected to the bracket member 10 is a fender bracket 36 having a third aperture 38 and a fourth aperture 40 . The third aperture 38 on the fender bracket 32 is aligned with the main aperture 30 of the U-bracket 14 , the first aperture 32 and the second aperture 34 . The fender bracket 32 has a fourth aperture 40 which is aligned with a support aperture 42 on the bracket member 10 .
The bracket member 10 also includes a slot 44 , which is formed as part of the bracket member 10 . The slot 44 is made by a first substantially flat portion 46 which is offset from a second substantially flat portion 48 and an extension 50 . The first flat portion 46 has an aperture 52 which is selectively in alignment with a corresponding aperture 54 formed on a tab 56 . The apertures 52 , 54 are used along with a socket 58 for allowing one of the externally visible components mentioned above, in this case a headlamp 60 , to be attached to the bracket member 10 . When the apertures 52 , 54 are aligned, the aperture 52 and corresponding aperture 54 will receive a protrusion having a detent (not shown) from the headlamp 60 . Once inserted, the tab 56 is moved in the slot 44 so as to offset the aperture 52 from the corresponding aperture 54 of the tab 56 . When the tab 56 is moved in the slot 44 , the aperture 54 becomes offset from the aperture 52 , and the aperture 54 has a narrow portion 62 which engages the detent of the headlamp 60 . The headlamp 60 also includes a ball (not shown) which is inserted into the socket 58 , allowing for the position of the headlamp 60 to be changed, and compensate for various tolerances. Once the protrusion is inserted through the apertures 52 , 54 , and the ball is inserted into the socket 58 , headlamp 60 is secured to the bracket member 10 .
The bracket member 10 is used as part of a system used for supporting various types of finish panels in an automobile, such as the fender 22 and fascia 24 mentioned above. Referring to FIG. 5 , the system includes a carrier member, which in this embodiment is a carrier 64 which is used for supporting various vehicle components, such as a radiator, hood, fan, fan shroud, windshield washer fluid container, various hoses, and the like. Attached on each side of the carrier 64 are lamp supports 66 . The lamp supports 66 are attached through the use of an adhesive bond and rivets 68 . The adhesive bond is placed between the carrier 64 and the lamp supports 66 , the rivets 68 are then attached and hold the carrier 64 and lamp supports 16 together until the adhesive bond cures.
Attached to each of the lamp supports 66 are the bracket members 10 , and a support member 70 . The bracket member 10 is attached to the carrier 64 through the use of fasteners, shown as bolts 72 inserted through a set of apertures 74 formed as part of the bracket member 10 , and a set of corresponding threaded apertures (not shown) formed in the carrier 64 , best seen in FIGS. 1-3 , 5 and 6 . The lamp supports 66 along with the bracket member 10 forms a component support structure. Also attached to each of the headlamp supports 66 is a center support 76 . The support member 70 and the center support 76 are used for supporting a contoured finish panel of the body of a vehicle, which in this embodiment is the fascia 24 . The fascia 24 is used to provide an aesthetically pleasing appearance and is typically the same color as the remaining body components.
The support member 70 is connected to the bracket member 10 through the use of an extension 78 which is connected to a lower bracket 80 through the use of a snap-fit connection, which allows the extension 78 to pivot about the bracket 80 ; the support member 70 is also connected to the lamp support 66 through the use of a fastener, such as a screw (not shown) inserted through a slot 82 in a flange 84 and through a corresponding aperture 86 in the lamp support 66 . The support member 70 also includes snaps 88 , the function of which will be described later, and a contoured surface 90 for supporting the fascia 24 .
The headlamp 60 is also attached to the lamp supports 66 through the use of an upper connector 92 and a lower connector 94 . The upper connector 92 , lower connector 94 , the slot 44 and tab 56 , and the ball and socket 58 form a second attachment structure for connecting the headlamp 60 to the lamp support 66 and bracket member 10 . The flange 84 and the slot 82 , and the corresponding aperture 86 form an attachment point; the extension 78 and bracket 80 form a third attachment structure for attaching the support member 70 to the lamp support 66 and the bracket member 10 .
Once the headlamp 60 is attached to the lamp support 66 and the bracket member 10 , the position of the support member 70 can be adjusted using the extension 78 and bracket 80 , along with the fastener inserted through the slot 82 and into the aperture 86 . The slot 82 is shaped so as to allow the position of the support member 70 to be adjusted during assembly relative to the lamp support 66 . Adjusting the position of the support member 70 relative to the lamp support 66 secures the position of the support member 70 , and therefore secures the position of the fascia 24 , relative to the headlamp 60 , allowing for control over the amount of space between the headlamp 60 and fascia 24 . The space between the headlamp 60 and fascia 24 is shown as a gap, generally at 96 , in FIG. 10 .
Referring to FIGS. 5 and 6 , the fascia 24 includes a set of extensions (not shown) having an angled tab (also not shown) which are received into the snaps 88 of the support member 70 . The snaps 88 have a frame member 98 and an aperture 100 . The angled tab of the fascia 24 is inserted through the aperture 100 , and through the use of a snap-fit connection, the extensions of the fascia are connected to the frame member 86 . The contoured surface 90 of the support member 70 provides support for the fascia 24 .
The center support 76 also includes a contoured surface 102 , which also provides support for the fascia 24 . The center support 76 includes a centering aperture 104 , a series of grille snaps 106 having an aperture 108 , and top snaps 110 having an aperture 112 . Another externally visible member, which in this embodiment is an exterior body component in the form of a grille (not shown), is attached to the center support 76 through the use of the grille snaps 106 . The grille has extensions (not shown) which include angled tabs, and are inserted into the grille snaps 106 in the same manner as the extensions of the fascia 24 are inserted into the snaps 88 . The grille is properly aligned with the center support 76 by using the centering aperture 104 . After the grille is attached, the fascia 24 is attached using a set of extensions (not shown) having an angled tab and contact surface which are similar to the extensions inserted into the snaps 88 , and are inserted into the top snaps 110 in a similar manner that the extensions are inserted into the snaps 88 .
As the fascia 24 is attached to the support member 70 , the flange 26 of the fascia 24 is inserted into the U-bracket 34 of the fascia attachment 12 , along with the flange 28 of the fender 30 . A single fastener, such as a screw, is inserted through the main aperture 30 , the first aperture 32 , the second aperture 34 , and third aperture 38 , rigidly connecting the fender 22 , fascia 24 , and the bracket member 10 . The third aperture 38 of the fender bracket 36 is aligned with the main aperture 30 of the U-bracket 34 because of a guide pin 114 which extends through a secondary aperture 116 on the fender bracket 36 .
The center support 76 is formed such that once the grille and the fascia 24 are both attached to the center support 76 , the desired distance between the grille and fascia 24 is achieved to provide an aesthetically pleasing appearance. The top snaps 110 , and extensions of the fascia 24 form a first attachment assembly for connecting the fascia 24 to the center support 76 , and the grille snaps 106 along with the extensions of the grille form a second attachment assembly for connecting the grille to the center support 76 .
It should be noted that the fascia 24 could also be replaced with a top cap. The top cap would also have extensions which would be received by the snaps 88 of the support member 70 and the top snaps 110 of the center support 76 , and supported by the contoured surface 90 of the support member 70 and the contoured surface 102 of the center support 76 in the same manner as the fascia 24 .
While it has been shown that the bracket member 10 has been used with the carrier 64 and lamp supports 66 , the bracket member 10 is made through a forming process, such as injection molding, and can be made to fit any type of vehicle having any type of fascia 24 or top cap.
The description of the invention is merely exemplary in nature and, thus, variations that do not depart from the essence of the invention are intended to be within the scope of the invention. Such variations are not to be regarded as a departure from the spirit and scope of the invention. | The present invention is a component for providing alignment between at least two external components. The present invention is a bracket member having at least two attachment structures, and at least two externally visible components connected to the at least two attachment structures, and the at least two attachment structures provide adjustable positioning between the at least two externally visible components connected to the at least two attachment structures such that the position off the at least two externally visible components can be adjusted relative to one another. | 1 |
GOVERNMENT INTEREST
The invention disclosed herein may be manufactured, used and licensed by or for the United States Government.
This application is a continuation-in-part of application Ser. No. 08/106,836, filed on Aug. 16, 1993 now abandoned.
BACKGROUND OF THE INVENTION
In modern warfare the success of a mission is frequently dependent upon using the proper munition against the intended target. Munitions which use shaped charges having a single massive high velocity penetrator may be suitable against an armored vehicle such as a tank or armored personnel carrier, but ineffective against light, dispersed targets such as a group of trucks, supply vehicles, missile launchers or communication stations. In the past, an aircraft armed with a multiplicity of weapons to meet a variety of targets meant a possible loss of ability to counter a threat larger than anticipated of one particular kind. The high cost of guided missiles makes it extremely important that the warhead be suitable for defeating the intended target and having the capability of quickly and selectively changing the shape of the warhead's penetrating pattern. There are presently artillery fired target seeking munitions having applications requiring the ability to select to project either a single penetrator or a number of small penetrators or fragments spread out in a controlled pattern.
Prior art devices have tried to solve this problem of selectable effects through the use of different or multiple initiation points for the shape charge munition. The complex shape of the detonation wave produced was intended to interact with the liner causing it to break up into a number of individual fragments. The problem with this approach is that it requires a relatively complex initiation scheme. A simpler approach was therefore sought and may be found in the present invention hereinafter described.
SUMMARY OF THE INVENTION
The present invention relates to an apparatus and method that allows selection of two or more effect when an explosively formed penetrator (EFP) warhead is detonated.
An object of the present invention is to provide a mechanical method for an explosively formed penetrator (EFP) which utilizes two or more rod networks mounted in an overlapping pattern to allow production of more than one controlled fragment size.
Another object of the present invention is to provide a rod array for an EFP which allows production of a multiplicity of fragment sizes.
Another object of the present invention is to provide a mechanical selection device for an EFP that is simple to manufacture, inexpensive and adaptable to almost any warhead design.
A further object of the present invention is to provide an EFP system that is effective against armored targets, such as tanks, armored personnel carriers and light armored targets such as trucks, missile launchers, and communication stations.
For a better understanding of the present invention, together with other and further objects thereof, reference is made to the following description taken in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an isometric view of a parachute delivered selectable effects warhead munition showing a long rod explosively formed penetrator suitable for defeating armored targets and where a multipenentator rod network has been discarded prior to activation.
FIG. 2 is an isometric view of a parachute delivered selectable effects warhead munition showing a multiple explosively formed penetrators suitable for defeating light armed targets.
FIG. 3 is an exploded view of a typical selectable effects EFP warhead.
FIG. 4 is a cross-sectional view of an EFP warhead with a rod array in place, taken along line 1--1 of FIG. 5.
FIG. 5 is an isometric view of an EFP warhead with a rod array in place.
FIG. 6 is a target plate showing the fragmentation pattern of a rod array shown in FIG. 5.
FIG. 7 shows an EFP warhead with a (detachable) screen array, to replace the rod array shown in FIG. 5.
FIG. 8 shows a device like in FIG. 7 except that the screen array is a honeycomb pattern.
Throughout the following description like reference numerals are used to denote like parts of the drawings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIGS. 1-3 a metal cylindrically cup-shaped housing 10 is supported by a parachute 12 which has been ejected by a carrier, not shown, to the target area. The housing 10 contains therein a cylindrically shaped explosive charge 14 such as octol. A round metal liner plate 16 is operatively disposed intermediate the explosive charge 14 and a mechanically selectively positioned rod array 18. FIG. 1 illustrates the application where multipenetrator rod network 18 has been discarded so that the munition when fired will produce a single high velocity rod shaped penetrator 20 capable of penetrating and defeating armored targets. FIG. 2 illustrates the application where the multipenetrator rod network 18 has not been discarded so that the munition when fired will propel the liner 16 through the rod array 18 producing a pattern of high velocity multiple explosively formed penetrator 22.
Referring now to FIGS. 4 and 5, the major components comprise the circular copper plate liner 16 positioned between the octol explosive charge 14 and the rod array 18 removably located on the open front end 24 of housing 10. The rear housing closed and 26 has an axially positioned detonator 28 located therein for initiating the explosive.
In operation when the explosive 14 is initiated by the detonator 28 it detonates causing the liner 16 to be accelerated in the direction opposite the ignition point. If the rod array 18 is not present, as shown in the FIG. 1 application, the plate liner 16 is formed into a single penetrator 20. If however, the rod array 18 is in place as shown in FIGS. 2-5, the liner 16 contacts the rod array 18 in the early stages of its motion. The inertia of the rod array 18 causes the plate liner 16 to break up along the lines of the rods 18' into a number of discrete fragments. For the example in FIGS. 4 and 5 the number of fragments produced would be nine. Two or more rod networks may be mounted in an overlapping pattern to allow production of more than one controlled fragment size for specific applications. Careful design of the rod array 18 allows production of almost any size fragment. The network of rods 18 is removed prior to warhead functioning when the normal EFP single penetrator formation is desired.
FIG. 6 illustrates the pattern produced on a one-inch aluminum target plate 30 by the impact of fragments from the liner of a test warhead similar to that illustrated in 5. In the test, the plate was located four feet in front of the test warhead. The octol explosive charge in the test warhead, not shown, was 2.5 inches in diameter and 2.5 inches high. The network of rods (70) shown in FIG. 7 may be removed by detaching the screws or bolts shown there (71). It is considered possible to have the rod array removed, in-flight, (when desired) upon radio signal command to activate explosives which will cut such screws or bolts. The rod array plate will then quickly become detached in flight. Such system would eliminate need to physically remove the rod arrays from each warhead, when a mission requires single penetrator formations. Also, it allows a mission to be changed at, or delayed to, the last minute, in combat, without returning to base for changes. FIG. 8 shows a different possible pattern for the rod array, where the pattern is honeycomb in shape.
The concept of employing an array of rods or wires to control the fragmentation of a warhead component can also be applied to other warhead configurations. For example, wrapping a wire screen around the surface of a cylindrical warhead can control the fragmentation of the side wall.
While a specific embodiment of the invention has been shown and described in detail to illustrate the application of the principles of the invention, it will be understood that the invention may be embodied otherwise without departing from said principles. | An apparatus and method for producing a selectable effects explosively fod penetrator warhead having the ability to defeat either single armored targets or a multiplicity of lightly armored targets. | 5 |
BACKGROUND OF THE INVENTION
The present invention relates to a fender designed to protect a vessel by reducing the impact of the docking vessel through absorption of the kinetic energy thereof.
A fender 9 conventionally used in the art is exemplified by a circle-type fender made of one piece rubber material having a sectional shape as shown in FIG. 20 A. The circle-type fender 9 includes: a first bumper member 91 formed in a cylindrical shape of a constant outside diameter and constructed such that one end of the cylindrical body defines a distal end 9 a of the fender 9 and serves as a fixing portion for fixing an impact receiving plate (not shown) directly coming into contact with a vessel; and a second bumper member 92 formed in a hollow conical shape wherein one end thereof is connected to the other end of the cylindrical body of the first bumper member 91 while the other end thereof defines a fix portion to be fixed to a fixing surface Q on a dock and wherein the latter end thereof has a greater outside diameter than the former end thereof. Indicated at 93 is a flange actually functioning to fix the fix portion of the second bumper member 92 to the fixing surface Q.
When receiving a compressive force from the docking vessel, the fender 9 is compressively deformed as described below. First, the fender 9 develops a reaction force against the compressive force. When the fender can no more withstand the compressive force, it starts to buckle at an outer periphery of a connection portion CP between the first bumper member 91 and the second bumper member 92 and at an inner periphery of a buckling position BP of the second bumper member 92 . Subsequently, as shown in FIG. 20B, the whole body of the fender 9 is deformed into a tightly folded shape with an outer periphery 91 a of the first bumper member 91 and an outer periphery 92 a of the second bumper member 92 as well as areas 92 b , 92 c above and below the buckling position BP on the inner periphery of the second bumper member 92 coming into contact with each other. Then, the tightly folded fender 9 with no more portion to be buckled forms a single rubber mass which is further compressively deformed.
If this process is expressed by a distortion-reaction force characteristic curve plotting the amount of distortion of the compressed fender 9 relative to the reaction force developed in the fender 9 , a solid curved line of FIG. 21 is obtained. Specifically, a line portion between the origin O and Maximum Point A corresponds to a period between a normal state shown in FIG. 20A and a state just before the fender starts to buckle, yielding to the compressive force. During this period, the compressed fender 9 develops the reaction force, trying to restore itself to its initial shape. The reaction force increases as the amount of distortion becomes greater. Upon buckling, however, the fender 9 loses most of the reaction force. Hence, the reaction force declines during the time that the fender 9 is crushed into the state of FIG. 20 B. This time period corresponds to a line portion between Maximum Point A and Minimum Point C of the characteristic curve. In the state of FIG. 20B, the whole body of the fender 9 behaves as a single rubber mass as mentioned supra, developing the reaction force again. Therefore, the reaction force substantially linearly rises from Minimum Point C.
The practically useful range of the fender 9 with such a characteristic curve is limited to a range between the origin O and a point B representing the same level of reaction force as Maximum Point A. The useful range as expressed in terms of distortion is limited to the range of not more than D. This is because a distortion in excess of D means an excessive reaction force which, in turn, will cause damage to the vessel or to the fender 9 itself. The amount of energy that the fender 9 can absorb through distortion D within the allowed range is represented by an area S 1 of a region enclosed by the characteristic curve represented by the solid line, a horizontal axis O-D, and a vertical line B-D.
It is generally thought idealistic that the fender is capable of absorbing such an amount of energy that corresponds to the combination of the above area S, and an area S 2 of a region enclosed by the characteristic curve and a horizontal line A-B. However, the fender is actually capable of absorbing energy of an amount reduced by that represented by the area S 2 , thus reduced in the energy absorption efficiency.
In this connection, study has been made to increase the energy-absorption capacity of the fender 9 . For instance, it is contemplated to increase thicknesses T 1 and T 2 of the first and second bumper members 91 , 92 , as shown in FIG. 22A, thereby to increase the reaction forces of the bumper members 91 , 92 against compression.
Unfortunately, this approach has the following problem. With a smaller distortion than in the case of FIGS. 20A, 20 B, the fender 9 is buckled into a completely folded state, as shown in FIG. 22B, wherein the outer periphery 91 a of the first bumper member 91 and the outer periphery 92 a of the second bumper member 92 as well as the areas 92 b , 92 c above and below the buckling position BP on the inner periphery of the second bumper member 92 come into contact with each other, leaving no more portion to be buckled. That is, with a smaller distortion than in the case of FIG. 20B, the buckled fender 9 starts to behave as the single rubber mass.
As indicated by a dash-single-dot curved line in FIG. 23, this results in a smaller distortion D′ than the distortion D in the case of FIGS. 20A, 20 B, the distortion D′ corresponding to the reaction force which, after buckling, starts to re-increase and reaches a point B′ representing the same level as Maximum Point A′. That is, a width of a constant load area in which the fender is principally involved in the energy absorption, or the range A-B between Maximum Point A and the point B of the characteristic curve is reduced to a range A′-B′. Thus, the fender is reduced in the energy-absorption capacity after buckling.
Therefor, the arrangement of FIG. 22A suffers a problem that despite the increased size corresponding to the increased thickness as described above, the fender cannot attain the increased energy-absorption capacity corresponding to the size increase or any increase in the energy-absorption capacity at all.
SUMMARY OF THE INVENTION
A first object of the invention is to provide a novel fender capable of approximating a distortion-reaction force characteristic curve within an allowed range of distortion to an idealistic curve representing a substantially constant value of reaction force after the maximum point.
A second object of the invention is to provide a novel fender capable of presenting the greatest possible energy-absorption capacity within the allowed range of distortion.
According to the invention of claim 1, a fender for absorbing the impact of a vessel, formed of rubber and fixed to a fixing surface of a dock as having an impact receiving plate secured to a distal end of its body, the fender comprising: a first bumper member formed in a cylindrical shape of a constant outside diameter and defining at one end of the cylindrical body thereof a fixing portion for the impact receiving plate; a second bumper member connected at one end to the other end of the cylindrical body of the first bumper member, defining at the other end thereof a fix portion to be fixed to the fixing surface, formed in a hollow conical shape with its latter end greater in outside diameter than its former end, and buckling radially outwardly upon receiving a compressive force from the vessel thereby absorbing the impact of the vessel; and a step formed along an outer periphery of a connection portion between the two bumper members, the step defined by the former end of the second bumper member having a greater outside diameter than the latter end of the first bumper member.
By virtue of a step 14 on the outer periphery of the connection portion between two bumper members 11 , 12 , such as shown in FIGS. 1 and 2A for example, the fender of claim 1 can accomplish the increase in the aforesaid distortion D, as compared with the conventional fender 9 without the step on the outer periphery of the connection portion CP. Specifically, the provision of the step 14 provides a configuration wherein an outer periphery 11 a of the first bumper member 11 is somewhat recessed from an outer periphery 12 a of the second bumper member 12 . As a result, when the fender is buckled, a greater distortion D than in the conventional fender 9 is involved in bringing the outer peripheries 12 a , 12 a into contact with each other, as shown in FIG. 2 B.
As shown in FIG. 20B, the conventional fender 9 in the buckled state contains a cavity CV between the bent bumper members 91 , 92 . The cavity CV is responsible for a greater decline of the reaction force after Maximum Point A. That is, a deformation involved in crushing the cavity CV is added to the normal deformation by buckling as mentioned supra, so that the fender 9 encounters the correspondingly increased amount of deformation after buckling. This results in the greater decline of the reaction force after Maximum Point A. In contrast, the arrangement of claim 1 is adapted to reduce or totally eliminate the cavity between the bent members 11 , 12 by virtue of a corner of the step 14 caught in the cavity, as shown in FIG. 2 B. Thus, the decline of the reaction force after Maximum Point A is reduced.
According to the arrangement of claim 1, the synergy between these effects not only approximates the characteristic curve as close as possible to the idealistic curve but also enables further increase in the energy-absorption capacity and the energy absorption efficiency of the fender.
According to the invention of claim 2, the fender of claim 1 is characterized in that the first bumper member and the second bumper member share the same inside diameter at the connection portion and that a ratio T 1 /T 2 is in the range of 0.8 to 0.9, T 1 denoting a thickness of the first bumper member, T 2 denoting a thickness of the second bumper member.
If the ratio T 1 /T 2 is less than 0.8, the thickness T 2 of the second bumper member 12 is relatively increased.
This may result in a similar problem to that occurred in the case of FIGS. 22A, 22 B. Specifically, areas 12 b , 12 c above and below the buckling position BP on an inner periphery of the second bumper member 12 are brought into contact with each other by a smaller distortion and hence, the allowed distortion D is decreased. This leads to a reduced energy-absorption capacity after buckling.
If the ratio T 1 /T 2 exceeds 0.9, the step 14 may have an insufficient dimension for adequately offering the effect of claim 1. Specifically, when caught in the cavity between the bent of the first and second bumper members 11 , 12 , the step 14 may not be effective enough to reduce or totally eliminate the cavity. Thus, the decline of the reaction force after Maximum Point A cannot be reduced enough. Or the step 14 may not be effective enough to increase the distortion involved in bringing the outer peripheries 11 a , 12 a of the bumper members 11 , 12 into contact with each other. Thus, the distortion D cannot be increased enough.
In contrast, the arrangement of claim 2 is not likely to encounter these problems, further enhancing the effects of claim 1.
According to the invention of claim 3, the fender of claim 1 is characterized in that a ratio H 1 /H 0 is in the range of 0.1 to 0.3, H 1 denoting an axial height of the cylindrical body of the first bumper member, H 0 denoting an overall height of the fender with respect to the axis of the cylindrical body.
According to the invention of claim 4, the fender of claim 3 is characterized in that an angle θ 1 between the fixing surface and a generatrix of the conical body of the second bumper member is in the range of 70 to 80°.
If the overall height H 0 and the outside diameter D 1 of the first bumper member 11 are constant, the height H 1 and the angle θ 1 have a correlation. That is, as the height H 1 of the first bumper member 11 accounts for the greater proportion of the overall height H 0 , the angle θ 1 becomes the smaller, as shown in FIG. 8 . On the other hand, the angle θ 1 increases with decrease in the proportion of the height H 1 as shown in FIG. 9 .
If the height H 1 is below the above range or if the angle θ 1 exceeds the above range, the reaction force at buckling is increased because the height H 2 of the second bumper member 12 has a relatively increased proportion of the overall height H 0 . At the same time, the energy-absorption capacity as a whole is increased because the distortion of the fender involved in bringing the second bumper member 12 into a buckling process or the distortion thereof involved in buckling the second bumper member to limit is increased. Considering the characteristics of the fender, however, such a fender cannot serve a useful function because a width of a constant load area, that is, a range of the characteristic curve between Maximum Point A and the point B where the first bumper member 11 is in charge of the load is too small.
If the height H 1 exceeds the above range or if the angle θ 1 is below the above range, the reaction force at buckling is decreased because the height H 2 of the second bumper member 12 has a relatively decreased proportion of the overall height H 0 . At the same time, the distortion of the fender involved in bringing the second bumper member 12 into the buckling process or the distortion thereof involved in buckling the second bumper member to limit is decreased. Hence, the energy-absorption capacity as a whole tends to decrease.
In contrast, the arrangements of claims 3 and 4 are not likely to encounter these problems, further enhancing the effects of claim 1.
According to the invention of claim 5, a fender for absorbing the impact of a vessel, formed of rubber and fixed to a fixing surface of a dock as having an impact receiving plate secured to a distal end of its body, the fender comprises: a first bumper member formed in a cylindrical shape of a constant outside diameter and defining at one end of the cylindrical body thereof a fixing portion for the impact receiving plate; a second bumper member connected at one end to the other end of the cylindrical body of the first bumper member, defining at the other end thereof a fix portion to be fixed to the fixing surface, formed in a hollow conical shape with its latter end greater in outside diameter than its former end, and buckling radially outwardly upon receiving a compressive force from the vessel thereby absorbing the impact of the vessel; and a projection having a constant width and formed along a buckling position on an inner periphery of the second bumper member.
According to the arrangement of claim 5, the second bumper member 12 is buckled and clamp a projection 15 from top and bottom, as shown in FIG. 4C while the clamped projection 15 develops a counterforce against a compressive force applied thereto by being buckled. That is, the projection 15 contributes the counterforce against the buckling of the second bumper member 12 . This results in an increased reaction force which the buckled second bumper member 12 exhibits against the compressive force.
On the inner periphery of the second bumper member 12 , the areas 12 b , 12 c above and below the projection 15 are in somewhat recessed from the projection 15 . This also results in an increased distortion of the buckled fender which is involved in bringing the areas 12 b , 12 c into contact with each other.
Thus, the synergy between these effects increases the energy-absorption capacity of the fender as a whole.
According to the invention of claim 6, the fender of claim 5 is characterized in that a ratio W 1 /W 2 is in the range of 3/6 to 6/3, W 1 denoting a distance from the buckling position to an upper side of the projection along an axis of the conical body of the second bumper member, W 2 denoting a distance from the buckling position to a lower side of the projection along the axis of the conical body.
If the ratio W 1 /W 2 is less than 3/6, the upper side of the projection 15 is so close to the buckling position BP of the second bumper member 12 that the second bumper member 12 buckles only along the upper side of the projection 15 as shown in FIG. 12C for example. If the ratio W 1 /W 2 is in excess of 6/3, the lower side of the projection 15 is so close to the buckling position BP of the second bumper member 12 that the second bumper member 12 buckles only along the lower side of the projection 15 as shown in FIG. 13C for example. In either cases, the buckled second bumper member 12 cannot clamp the projection 15 from top and bottom well, thus, the effect of claim 5 may not be fully attained.
In contrast, the arrangement of claim 6 is not likely to encounter these problems, further enhancing the effects of claim 5.
According to the invention of claim 7, the fender of claim 6 is characterized in that a distance W 1 +W 2 between the upper side and the lower side of the projection along the axis of the conical body is in the range of 20 to 40% of a height H 2 of the second bumper member along the axis of the conical body.
If the distance W 1 +W 2 representative of the width of the projection 15 is less than 20% of the height H 2 , the projection 15 may not provide the adequate effects of claim 5. Specifically, the projection 15 may be too small to afford the aforesaid effect to increase the reaction force of the second bumper member 12 as it is buckled. If the distance W 1 +W 2 is in excess of 40% of the height H 2 , a similar result to that of the increased thickness of the whole body of the second bumper member 12 is produced. This leads to the same problem as in the case of FIGS. 22A, 22 B, decreasing the energy-absorption capacity after buckling.
In contrast, the arrangement of claim 7 is not likely to encounter these problems, further enhancing the effects of claim 5.
According to the invention of claim 8, the fender of claim 7 is characterized in that the projection is of a trapezoidal shape in section and has a projection height T 3 from the inner periphery of the second bumper member in the range of 5 to 15% of the thickness T 2 of the second bumper member.
If the height T 3 of the projection 15 of the trapezoidal sectional shape is less than 5% of the thickness T 2 of the second bumper member, the projection 15 may be too low to afford an adequate effect to increase the reaction force of the second bumper member 12 as it is buckled. It is also likely that the projection 15 is not effective enough to increase the distortion of the buckled fender involved in bringing the areas 12 b , 12 c above and below the projection 15 into contact with each other. That is, the provision of the projection 15 may not contribute the adequate effect. If the height T 3 of the projection 15 exceeds 15% of the thickness T 2 of the second bumper member, an excessive distortion of the fender may be involved in bringing the areas 12 b , 12 c into contact with each other, the areas 12 b , 12 c located above and below the projection 15 on the inner periphery of the second bumper member 12 . As a result, the fender is excessively distorted when both the areas 12 b , 12 c contact each other so that the reaction force rises sharply after this point of time, i.e., after the point C on the reaction force characteristic curve. That is, the fender is excessively compressed so that damage to the vessel or the fender itself may result.
In contrast, the arrangement of claim 8 is not likely to encounter these problems, further enhancing the effects of claim 5.
According to the invention of claim 9, the fender of claim 7 is characterized in that the projection is of a triangular shape in section and has a projection height T 3 from the inner periphery of the second bumper member in the range of 15 to 20% of the thickness T 2 of the second bumper member. Given the same width and height, the projection 15 of the triangular sectional shape has a smaller sectional area than the projection of the trapezoidal sectional shape. Accordingly, the projection is designed to have a greater projection height T 3 in order to accomplish the same degree of working effect as the projection of the trapezoidal sectional shape.
If the projection of the triangular sectional shape has a projection height T 3 of less than 15% of the thickness T 2 of the second bumper member 12 , the projection 15 may be too low to afford an adequate effect to increase the reaction force of the second bumper member 12 as it is buckled. It is also likely that the projection 15 is not effective enough to increase the distortion of the buckled fender involved in bringing the areas 12 b , 12 c above and below the projection 15 into contact with each other. That is, the provision of the projection may not contribute the adequate effect. If the height T 3 of the projection 15 exceeds 20% of the thickness T 2 of the second bumper member, an excessive distortion of the fender may be involved in bringing the areas 12 b , 12 c into contact with each other, the areas 12 b , 12 c located above and below the projection 15 on the inner periphery of the second bumper member 12 . The fender is excessively distorted when both the areas 12 b , 12 c contact each other so that the reaction force rises sharply after this point of time, i.e., after the point C on the reaction force characteristic curve. That is, the fender is excessively compressed so that damage to the vessel or the fender itself may result.
In contrast, the arrangement of claim 9 is not likely to encounter these problems, further enhancing the effects of claim 5.
According to the invention of claim 10, the fender of claim 5 further comprises a step along an outer periphery of a connection portion between the two bumper members, the step defined by the former end of the second bumper member having a greater outside diameter than the latter end of the first bumper member.
According to the arrangement of claim 10, the synergy between the effects of the arrangements of claims 1 and 5 not only provides the characteristic curve even closer to the idealistic curve but also enables further increase in the energy-absorption capacity and the energy absorption efficiency of the fender.
An analogous arrangement to the inventive arrangement is disclosed in Japanese Unexamined Patent Publication No.11(1999)-222833 which suggests the provision of a step on an outer periphery of a circle-type fender. However, this step is not provided at the connection portion between the first and the second bumper members but at a midportion of the second bumper member, which is far below the connection portion. Disposed at such a place, the step does not operate the same way as the aforementioned step of the invention. Therefore, the above fender cannot offer the working effect equivalent to that of the invention. Hence, this prior art is not construed as disclosing nor suggesting the present invention.
Japanese Unexamined Patent Publication No.7(1995)-229129 discloses a circle-type fender provided with a projection on its inner periphery. However, the projection is not disposed on the buckling position of the fender, as shown in FIG. 8, contained in this official gazette. The projection is disposed in a manner that the buckling position is positioned on a boundary between the projection and a smaller-thickness portion adjoining thereto. Therefore, this fender is no more than an equivalent to the aforementioned comparative examples of FIGS. 12A-12C and 13 A- 13 C, being unable to offer the same working effect as the invention. Hence, this prior art is not construed as disclosing nor suggesting the present invention.
Further, Japanese Examined Utility Publication No.49(1974)-15516 discloses a fender, the whole body of which is formed in a cylindrical shape of a constant outside diameter. This prior-art fender has an arrangement wherein the cylindrical body is formed with a projection at its buckling position. However, this prior art never teaches that the whole body of the fender consists of a first cylindrical bumper member of a constant outside diameter and a second bumper member of a hollow conical shape, nor that the projection is disposed on the buckling position of the second bumper member. Hence, this prior art is not construed as disclosing nor suggesting the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partially cutaway perspective view showing a fender according to one embodiment of the invention;
FIG. 2A is a vertical sectional view showing the fender of FIG. 1 in a normal, uncompressed state, whereas FIG. 2B is an enlarged vertical sectional view showing the fender compressed into a buckled state;
FIG. 3 is a partially cutaway perspective view showing a fender according to another embodiment of the invention;
FIG. 4A is a vertical sectional view showing the fender of FIG. 3 in a normal, uncompressed state, FIG. 4B is an enlarged sectional view showing a projection which is a principal part of the fender, and FIG. 4C is an enlarged vertical sectional view showing the fender compressed into a buckled state;
FIG. 5A is a vertical sectional view showing a fender according to another embodiment in a normal, uncompressed state, FIG. 5B is an enlarged sectional view showing a projection which is a principal part of the fender, and FIG. 5C is an enlarged vertical sectional view showing the fender compressed into a buckled state;
FIG. 6A is a vertical sectional view showing a fender according to another embodiment of the invention in a normal, uncompressed state, whereas FIG. 6B is an enlarged sectional view showing a projection which is a principal part of the fender;
FIG. 7A is a vertical sectional view showing a fender of Example 2 in a normal, uncompressed state whereas FIG. 7B is an enlarged vertical sectional view showing the fender compressed into a buckled state;
FIG. 8A is a vertical sectional view showing a fender of Example 3 in a normal, uncompressed state whereas FIG. 8B is an enlarged vertical sectional view showing the fender compressed into a buckled state;
FIG. 9A is a vertical sectional view showing a fender of Example 4 in a normal, uncompressed state whereas FIG. 9B is an enlarged vertical sectional view showing the fender compressed into a buckled state;
FIG. 10A is a vertical sectional view showing a fender of Comparative Example 2 in a normal, uncompressed state whereas FIG. 10B is an enlarged vertical sectional view showing the fender compressed into a buckled state;
FIG. 11 is a graph representing compressibility-reaction force characteristic curves of the fenders of Examples 1-4 and Comparative Examples 1-2;
FIG. 12A is a vertical sectional view showing a fender of Comparative Example 4 in a normal, uncompressed state, FIG. 12B is an enlarged sectional view showing a projection, and FIG. 12C is an enlarged vertical sectional view showing the fender compressed into a buckled state;
FIG. 13A is a vertical sectional view showing a fender of Comparative Example 5 in a normal, uncompressed state, FIG. 13B is an enlarged sectional view showing a projection, and FIG. 13C is an enlarged vertical sectional view showing the fender compressed into a buckled state;
FIG. 14 is a graph representing compressibility-reaction force characteristic curves of the fenders of Examples 5-6 and Comparative Examples 1, 3-5;
FIG. 15A is a vertical sectional view showing a fender of Example 8 in a normal, uncompressed state whereas FIG. 15B is an enlarged sectional view showing a projection;
FIG. 16A is a vertical sectional view showing a fender of Example 9 in a normal, uncompressed state whereas FIG. 16B is an enlarged sectional view showing a projection;
FIG. 17A is a vertical sectional view showing a fender of Example 10 in a normal, uncompressed state whereas FIG. 17B is an enlarged sectional view showing a projection;
FIG. 18A is a vertical sectional view showing a fender of Comparative Example 6 in a normal, uncompressed state whereas FIG. 18B is an enlarged sectional view showing a projection;
FIG. 19 is a graph representing compressibility-reaction force characteristic curves of the fenders of Examples 7-10 and Comparative Example 6;
FIG. 20A is a vertical sectional view showing a conventional fender in a normal, uncompressed state whereas FIG. 20B is an enlarged sectional view showing the fender compressed into a buckled state;
FIG. 21 is a graph representing a distortion-reaction force characteristic curve of the fender of FIG. 20A;
FIG. 22A is a vertical sectional view showing another conventional fender in a normal, uncompressed state whereas FIG. 22B is an enlarged vertical sectional view showing the fender compressed into a buckled state; and
FIG. 23 is a graph representing distortion-reaction force characteristic curves of the fenders of FIGS. 20 A and 22 A.
DESCRIPTION OF PREFERRED EMBODIMENTS
FIG. 1 is a partially cutaway perspective view showing a fender 1 according to one embodiment of the invention. FIG. 2A is a vertical sectional view of the above fender 1 .
The fender 1 comprises:
a first bumper member 11 formed in a cylindrical shape of a constant outside diameter D 1 , one end of the cylindrical body defining a distal end 1 a of the fender 1 and serving as a fixing portion for an impact receiving plate (not shown) directly coming into contact with a vessel;
a second bumper member 12 connected at one end to the other end of the cylindrical body of the first bumper member 11 , defining at the other end thereof a fix portion to be fixed to a fixing surface Q of a dock, and formed in a hollow conical shape with its latter end greater in outside diameter than its former end; and
a step 14 formed along an outer periphery of a connection portion between the two bumper members and defined by the former end of the second bumper member 12 having a greater outside diameter than the latter end of the first bumper member 11 . Indicated at 13 is a flange actually functioning to secure the fix portion of the second bumper member 12 to the fixing surface Q. The flange 13 is formed with through holes 13 a penetrated by fixing bolts (not shown). Although not illustrated, the flange 13 may have a reinforcement member, such as of a steel plate, embedded therein for the reinforcement purpose. Further, the first bumper member 11 may have a reinforcement member, such as of a steel plate, embedded in the former end thereof, i.e., the distal end 1 a of the fender 1 for the purposes of reinforcement and mounting of the impact receiving plate.
The first bumper member 11 and the second bumper member 12 are designed to share the same inside diameter D 3 at the connection portion. In this design, a ratio T 1 /T 2 between a thickness T 1 of the first bumper member 11 and a thickness T 2 of the second bumper member 12 is preferably in the range of 0.8 to 0.9, the ratio defining the width of the step 14 . The reason for this is mentioned in the foregoing. In order to further enhance the aforesaid working effect of the step 14 , the step of the wider width is more preferred. That is, the ratio T 1 /T 2 closer to 0.8 is more preferred.
A ratio H 1 /H 0 between a height H 1 of the first bumper member 11 and an overall height H 0 of the fender 1 , which is equal to a combined height of the first and the second bumper members 11 , 12 , is preferably in the range of 0.1 to 0.3. An angle θ 1 between a generatrix of the cone of the second bumper member 12 and the fixing surface Q is preferably in the range of 70 to 80°. The reasons for this are also mentioned in the foregoing. The ratio H 1 /H 0 ranging from 0.22 to 0.27 and the angle θ 1 ranging from 70 to 75° are more preferred in the light of a more preferred fender featuring a suitable reaction force characteristic as a useful fender and a great energy absorption.
The fender 1 is fabricated as follows. A mold is charged with an unvulcanized rubber compound and a plate-like reinforcement member to be embedded in one end of the first bumper member 11 and in the flange, as required. The mold has a shape corresponding to the shape of the fender 1 . The rubber compound is heated under pressure for vulcanization.
FIG. 3 is a partially cutaway perspective view showing a fender 1 according to another embodiment of the invention. FIG. 4A is a vertical sectional view of the above fender 1 whereas FIG. 4B is an enlarged sectional view of a projection 15 which is a principal part of the fender 1 .
The fender 1 comprises:
a first bumper member 11 formed in a cylindrical shape of a constant outside diameter D 1 , one end of the cylindrical body defining a distal end 1 a of the fender 1 and serving as a fixing portion for an impact receiving plate (not shown) directly coming into contact with a vessel;
a second bumper member 12 connected at one end to the other end of the cylindrical body of the first bumper member 11 , defining at the other end thereof a fix portion to be fixed to a fixing surface Q of a dock, and formed in a hollow conical shape with its latter end greater in outside diameter than its former end; and
a projection 15 having a constant width and formed along a buckling position BP on an inner periphery of the second bumper member 12 . Similarly to the foregoing embodiment, the second bumper member 12 is provided with the flange 13 at its latter end for securing the fender to the fixing surface Q. The flange 13 is formed with the through holes 13 a penetrated by the fixing bolts (not shown). Although not shown in the figure, the flange 13 may have the reinforcement member, such as of a steel plate, embedded therein for the reinforcement purpose. Further, the reinforcement member, such as of a steel plate, may also be embedded in the former end of the first bumper member 11 , i.e., the distal end 1 a of the fender 1 for the purposes of reinforcement and fixing of the impact receiving plate.
The projection 15 may preferably have a ratio W 1 /W 2 in the range of 3/6 to 6/3, W 1 denoting a distance from the buckling position BP of the second bumper member 12 to an upper side of the projection 15 , W 2 denoting a distance from the buckling position BP to a lower side of the projection 15 . The ratio W 1 /W 2 defines the position of the projection. A distance W 1 +W 2 between the upper side and the lower side of the projection 15 is preferably in the range of 20 to 40% of the height H 2 of the second bumper member 12 . The distance W 1 +W 2 defines the width of the projection 15 . The reasons for this are mentioned in the foregoing. In order to further enhance the aforesaid working effect of the projection 15 , the ratio W 1 /W 2 more preferably ranges from 4/5 to 5/4 and the distance W 1 +W 2 more preferably ranges from 25 to 35% of the height H 2 .
The projection 15 is formed in a trapezoidal shape in section. The projection 15 may preferably have a projection height T 3 from the inner periphery of the second bumper member 12 in the range of 5 to 15% of the thickness T 2 of the second bumper member 12 . The reason for this is also mentioned in the foregoing. The projection height T 3 is more preferably in the range of 7 to 9% of the thickness T 2 from the standpoint of further enhancing the aforesaid working effect of the projection 15 .
FIG. 5A is a vertical sectional view showing a fender 1 according to a still another embodiment of the invention. FIG. 5B is an enlarged sectional view of the projection 15 which is the principal part of the fender 1 .
The fender of this embodiment differs from the arrangement of FIGS. 4A, 4 B in that the projection has a triangular sectional shape rather than the trapezoidal shape. Other parts are the same as those of the foregoing embodiments and represented by the same reference characters, respectively.
The projection 15 with the triangular sectional shape may preferably have a projection height T 3 from the inner periphery of the second bumper member 12 in the range of 15 to 20% of the thickness T 2 of the second bumper member 12 . The reason for this is also mentioned in the foregoing. The projection height T 3 is more preferably in the range of 16 to 18% of the thickness T 2 from the standpoint of positively preventing the damage to the vessel or to the fender itself and of further enhancing the aforesaid working effect of the projection 15 .
FIG. 6A is a vertical sectional view showing a fender 1 according to another embodiment of the invention. FIG. 6B is an enlarged sectional view showing a projection 15 which is the principal part of the fender 1 .
The fender 1 of this embodiment is characterized by inclusion of both the step 14 and the projection 15 . The synergistic effect of the two portions contributes a characteristic curve even closer to the ideal curve and further increases the energy-absorption capacity and the energy absorption efficiency of the fender. Other parts are the same as those of the forgoing embodiments and represented by the same reference characters, respectively.
It is preferred that the respective parts have the same dimensions, shapes and the like as those of the forgoing embodiments.
That is, the first and second bumper members 11 , 12 are designed to share the same inside diameter D 3 at the connection portion between the two members 11 , 12 . In this design, the ratio T 1 /T 2 between the thickness T 1 of the first bumper member 11 and the thickness T 2 of the second bumper member 12 is preferably in the range of 0.8 to 0.9, the ratio defining the width of the step 14 . Particularly, the ratio closer to 0.8 is more preferred.
The ratio H 1 /H 0 between the height H 1 of the first bumper member 11 and the overall height H 0 of the fender 1 is preferably in the range of 0.1 to 0.3 and more preferably of 0.22 to 0.27. The second bumper member 12 may have the angle θ 1 between the generatrix of the cone body and the fixing surface Q preferably in the range of 70 to 80 20 and more preferably of 70 to 75°.
The ratio W 1 /W 2 between the distance W 1 from the buckling position BP of the second bumper member 12 to the upper side of the projection 15 and the distance W 2 from the buckling position BP to the lower side of the projection 15 is preferably in the range of 3/6 to 6/3, and more preferably of 4/5 to 5/4.
The distance W 1 +W 2 between the upper side and the lower side of the projection 15 is preferably in the range of 20 to 40%, and more preferably of 25 to 35% of the height H 2 of the second bumper member 12 .
The projection 15 is formed in a trapezoidal shape in section. The projection 15 may preferably have the projection height T 3 from the inner periphery of the second bumper member 12 in the range of 5 to 15% and more preferably of 7 to 9% of the thickness T 2 of the second bumper member 12 .
The projection 15 may have a triangular sectional shape, the illustration of which is dispensed with. Such a projection 15 may have the projection height T 3 from the inner periphery of the second bumper member 12 in the range of 15 to 20% and more preferably of 16 to 18% of the thickness T 2 of the second bumper member 12 .
It is to be noted that the arrangement of the fender of the invention is not limited to the embodiments described in the foregoing but various changes and modifications may be made thereto within the scope and spirits of the invention.
EXAMPLES
The invention will be described in more detail by way of reference to the following examples and comparative examples.
Example 1
A circle-type fender 1 was fabricated as follows. The following materials were charged in a mold and heated under pressure for vulcanizing a rubber base material. Thus was obtained the fender having the general appearance shown in FIG. 1 and the sectional shape shown in FIG. 2A as well as dimensions and an angle listed in Table 1.
A rubber compound: a rubber base material comprising a rubber mixture containing natural rubber and butadiene rubber in a weight ratio of 6:4;
A reinforcement member in one end of the first bumper member 11 : a disk-like steel plate having a thickness of 28 mm and an outside diameter of 650 mm and including a through hole of inside diameter of 270 mm at its center; and
A reinforcement member in the flange 13 : a disk-like steel plate having a thickness of 28 mm and an outside diameter of 1470 mm and including a through hole of inside diameter of 710 mm at its center.
TABLE 1
T 1
220 mm
T 2
244 mm
T 1 /T 1
0.9
H 0
1000 mm
H 1
250 mm
H 1 /H 0
0.25
θ 1
72.5°
D 1
680 mm
D 2
1500 mm
Example 2
The same rubber compound and two types of reinforcement members as in Example 1 were used to fabricate a circle-type fender 1 having the sectional shape of FIG. 7A as well as dimensions and an angle listed in Table 2.
TABLE 2
T 1
220 mm
T 2
275 mm
T 1 /T 2
0.8
H 0
1000 mm
H 1
250 mm
H 1 /H 0
0.25
θ 1
72.5°
D 1
680 mm
D 2
1500 mm
Example 3
The same rubber compound and two types of reinforcement members as in Example 1 were used to fabricate a circle-type fender 1 having the sectional shape of FIG. 8A as well as dimensions and an angle listed in Table 3.
TABLE 3
T 1
220 mm
T 2
244 mm
T 1 /T 2
0.9
H 0
1000 mm
H 1
300 mm
H 1 /H 0
0.30
θ 1
70.0°
D 1
680 mm
D 2
1500 mm
Example 4
The same rubber compound and two types of reinforcement members as in Example 1 were used to fabricate a circle-type fender 1 having the sectional shape of FIG. 9A as well as dimensions and an angle listed in Table 4.
TABLE 4
T 1
220 mm
T 2
244 mm
T 1 /T 2
0.9
H 0
1000 mm
H 1
100 mm
H 1 /H 0
0.10
θ 1
80.0°
D 1
680 mm
D 2
1500 mm
Comparative Example 1
The same rubber compound as in Example 1 and the following two reinforcement members were used to fabricate a circle-type fender 1 having the conventional sectional shape shown in FIG. 20A as well as dimensions and an angle listed in Table 5.
A reinforcement member in one end of the first bumper member 11 : a disk-like steel plate having a thickness of 28 mm and an outside diameter of 670 mm and including a through hole of inside diameter of 270 mm at its center; and
A reinforcement member in the flange 13 : the same steel plate as in Example 1
TABLE 5
T 1
230 mm
T 2
230 mm
T 1 /T 2
1.0
H 0
1000 mm
H 1
250 mm
H 1 /H 0
0.25
θ 1
72.5°
D 1
700 mm
D 2
1500 mm
Comparative Example 2
The same rubber compound as in Example 1 and the following two reinforcement members were used to fabricate a circle-type fender 1 having the sectional shape of FIG. 10A as well as dimensions and an angle listed in Table 6.
A reinforcement member in one end of the first bumper member 11 : a disk-like steel plate having a thickness of 28 mm and an outside diameter of 690 mm and including a through hole of inside diameter of 270 mm at its center; and
A reinforcement member in the flange 13 : the same steel plate as in Example 1
TABLE 6
T 11
240 mm
T 12
216 mm
T 2
240 mm
T 11 /T 2
1.0
T 12 /T 2
0.9
H 0
1000 mm
H 1
250 mm
H 1 /H 0
0.25
θ 1
72.5°
D 1
720 mm
D 2
1500 mm
Table 7 tabulates principal dimensions of the above examples and comparative examples.
TABLE 7
Thickness(mm)
Height(mm) H 0 = 1000
Angle θ 1
T 1
T 2
T 1 /T 2
H 1
H 1 /H 0
(degree)
Ex.1
220
244
0.9
250
0.25
72.5
Ex.2
220
275
0.8
250
0.25
72.5
Ex.3
220
244
0.9
300
0.30
70.0
Ex.4
220
244
0.9
100
0.10
80.0
C.Ex.1
230
230
1.0
250
0.25
72.5
C.Ex.2
T 11 : 240
240
1.0
250
0.25
72.5
T 12 : 216
0.9
Compressive Test
The fenders of the above examples and comparative examples were each examined as follows. The former end of the first bumper member was mounted to a movable head of a 500 ton hydraulic press via a spacer analogous to the impact receiving plate, the spacer having the same diameter as the first bumper member and a thickness of 200 mm. The flange on the latter end of the second bumper member was fixed to a stationary head of the hydraulic press. The fender was compressed by the hydraulic press to determine the distortion (compressibility)-reaction force characteristic. The compressibility was determined by the following expression:
Compressibility (%)=( H 0 −H 0 ′)/H 0 ×100
where H 0 denotes the overall height of the fender in initial shape and H 0 ′ denotes the overall height of the compressed fender. The results are shown in the graph of FIG. 11 .
As seen from FIG. 11, the fender 9 of comparative Example 1, as the conventional example, had a small compressibility of 60% representing the distortion D at the time when the reaction force, re-increased again, reached the point B representing the same level of reaction force at Maximum Point A. The following was found by continuing the observation of how the compressed fender deformed. After buckling, the fender 9 of Comparative Example 1 assumed the position of FIG. 20B with a smaller distortion than the Examples to be described later, the position wherein the outer peripheries 91 a , 92 a of both the members 91 , 92 came into contact with each other. This was because the outer peripheries 91 a , 92 a defined one continuous, step-free surface.
It was also found that the fender 9 of Comparative Example 1 presented a small percentage reaction force of 87.5% at Minimum Point C based on the reaction force at Maximum Point A, thus suffering a great decline in the reaction force after buckling, i.e., after Maximum Point A. The examination of a sectional shape of the buckled fender revealed that, as shown in FIG. 20B, the fender contained a large cavity CV between the bent members 91 , 92 .
The fender 9 of Comparative Example 2 was also determined to have a small compressibility of 58% representative of the distortion D, the fender wherein the first bumper member 91 was formed in a conical shape with one end having a greater diameter than the other end, the former end having a greater thickness T 11 than that T 12 of the latter end. The following was found by continuing the observation of how the compressed fender deformed. After buckling, the fender 9 of Comparative Example 2 assumed the position of FIG. 10B with a smaller distortion than the Examples to be described later, the position wherein the outer peripheries 91 a , 92 a of both the members 91 , 92 came into contact with each other. This was because the outside diameter of the first bumper member 91 was not constant but increased toward its former end, although the outer peripheries 91 a , 92 a included the step.
It was also found that the fender 9 of Comparative Example 2 presented a percentage reaction force of 97.0% at Minimum Point C based on the reaction force at Maximum Point A, thus having a small decline in the reaction force after buckling, i.e., after Maximum Point A. The examination of a sectional shape of the buckled fender revealed that a corner of a step 94 formed between the outer peripheries 91 a , 92 a of the members 91 , 92 was caught in the buckled portion, eliminating the cavity thereat.
In contrast, all the fenders 1 of Examples 1-4 were determined to have great comprehensibilities of 62 to 67% representative of the distortion D. The following was found by continuing the observation of how the compressed fender deformed. After buckling, the fenders 1 of the Examples assumed positions, as shown in FIGS. 2B, 7 B, 8 B and 9 B, with greater distortions than Comparative Examples 1-2, the positions wherein the outer peripheries 11 a , 12 a of both the members 11 , 12 came into contact with each other.
It was also found that all the fenders 1 of the Examples had percentage reaction forces at Minimum Point C of 92.5 to 97.5% based on the reaction force at Maximum Point A, thus presenting small declines in the reaction force after buckling, i.e., after Maximum Point A. The examination of sectional shapes of the buckled fenders revealed that a corner of the step 14 formed between the outer peripheries 11 a , 12 a of the members 11 , 12 was caught in the buckled portion, eliminating the cavity thereat.
A comparison of Examples 1, 3 and 4 showed the following tendencies, these Examples having the same ratio T 1 /T 2 but different ratios H 1 /H 2 and angles θ 1 . With increase in the ratio H 1 /H 2 and with decrease in the angle θ 1 , the overall energy-absorption capacity tends to decline. On the other hand, as the ratio H 1 /H 0 decreases and the angle θ 1 increases, the constant load area for the first bumper member 11 becomes smaller. The results are tabulated in Table 8.
TABLE 8
Reaction force drop at Min.
Compressibility (%)
Point C (%) *1
representing distortion D
Ex. 1
92.5
63
Ex. 2
95.0
65.5
Ex. 3
97.5
65
Ex. 4
96.5
62.5
C. Ex. 1
87.5
60
C. Ex. 2
97.0
58
*1 percentage reaction force based on the reaction force at Maximum Point A
Example 5
A circle-type fender 1 was fabricated as follows.
The following materials were charged in a mold and heated under pressure for vulcanizing a rubber base material.
Thus was obtained the fender having the general appearance shown in FIG. 3 and the sectional shape shown in FIGS. 4A, 4 B as well as dimensions and an angle listed in Table 9. A projection 15 was of a trapezoidal shape in section, having dimensions listed in Table 10.
A rubber compound: a rubber base material comprising a rubber mixture containing natural rubber and butadiene rubber in a weight ratio of 6:4;
A reinforcement member in one end of the first bumper member 11 : a disk-like steel plate having a thickness of 28 mm and an outside diameter of 670 mm and including a through hole of inside diameter of 270 mm at its center; and
A reinforcement member in the flange 13 : a disk-like steel plate having a thickness of 28 mm and an outside diameter of 1470 mm and including a through hole of inside diameter of 730 mm at its center.
TABLE 9
T 1
230 mm
T 2
230 mm
T 1 /T 2
1.0
H 0
1000 mm
H 1
250 mm
H 2
750 mm
H 1 /H 0
0.25
θ 1
72.5°
D 1
700 mm
D 2
1500 mm
TABLE 10
H 3
375 mm
T 3
20 mm
T 3 /T 2 × 100
8.7%
W 1
100 mm
W 2
125 mm
W 3
50 mm
W 4
50 mm
W 1 /W 2
4/5
W 1 + W 2
225 mm
(W 1 + W 2 )/H 2 × 100
30.0%
Example 6
The same rubber compound and two types of reinforcement members as in Example 5 were used to fabricate a circle-type fender 1 having the sectional shape shown in FIGS. 5A, 5 B as well as dimensions and an angle listed in Table 11. A projection 15 was of a triangular shape in section, having dimensions listed in Table 12.
TABLE 11
T 1
230 mm
T 2
230 mm
T 1 /T 2
1.0
H 0
1000 mm
H 1
250 mm
H 2
750 mm
H 1 /H 0
0.25
θ 1
72.5°
D 1
700 mm
D 2
1500 mm
TABLE 12
H 3
375 mm
T 3
40 mm
T 3 /T 2 × 100
17.4%
W 1
100 mm
W 2
125 mm
W 1 /W 2
4/5
W 1 + W 2
225 mm
(W 1 + W 2 )/H 2 × 100
30.0%
Comparative Example 3
The same rubber compound and two types of reinforcement members as in Example 5 were used to fabricate a circle-type fender 1 having the conventional sectional shape shown in FIG. 22A as well as dimensions and an angle listed in Table 13.
TABLE 13
T 1
265 mm
T 2
265 mm
T 1 /T 2
1.0
H 0
1000 mm
H 1
250 mm
H 2
750 mm
H 1 /H 0
0.25
θ 1
72.5°
D 1
770 mm
D 2
1500 mm
Comparative Example 4
The same rubber compound and two types of reinforcement members as in Example 5 were used to fabricate a circle-type fender 1 having a sectional shape shown in FIGS. 12A, 12 B as well as dimensions and an angle listed in Table 14. A projection 15 was of a trapezoidal shape in section, having dimensions listed in Table 15.
TABLE 14
T 1
230 mm
T 2
230 mm
T 1 /T 2
1.0
H 0
1000 mm
H 1
250 mm
H 2
750 mm
H 1 /H 0
0.25
θ 1
72.5°
D 1
700 mm
D 2
1500 mm
TABLE 15
H 3
375 mm
T 3
20 mm
T 3 /T 2 × 100
8.7%
W 1
50 mm
W 2
175 mm
W 3
25 mm
W 4
125 mm
W 1 /W 2
2/7
W 1 + W 2
225 mm
(W 1 + W 2 )/H 2 × 100
30.0%
Comparative Example 5
The same rubber compound and two types of reinforcement members as in Example 5 were used to fabricate a circle-type fender 1 having a sectional shape shown in FIGS. 13A, 13 B as well as dimensions and an angle listed in Table 16. A projection 15 was of a trapezoidal shape in section, having dimensions listed in Table 17.
TABLE 16
T 1
230 mm
T 2
230 mm
T 1 /T 2
1.0
H 0
1000 mm
H 1
250 mm
H 2
750 mm
H 1 /H 0
0.25
θ 1
72.5°
D 1
700 mm
D 2
1500 mm
TABLE 17
H 3
375 mm
T 3
20 mm
T 3 /T 2 × 100
8.7%
W 1
200 mm
W 2
25 mm
W 3
125 mm
W 4
25 mm
W 1 /W 2
8/1
W 1 + W 2
225 mm
(W 1 + W 2 )/H 2 × 100
30.0%
Principal dimensions of the above Examples, Comparative Examples and Comparative Example 1 are tabulated in Table 18.
TABLE 18
T 3 /T 2 ×
(W 1 + W 2 )/
T 2
T 3
100
H 3
W 1
W 2
W 1 /W 2
W 1 + W 2
H 2 × 100
Ex.5
230
20
8.7
375
100
125
4/5
225
30.0
EX.6
230
40
17.4
375
100
125
4/5
225
30.0
CEx.1
230
—
—
375
—
—
—
—
—
CEx.3
265
—
—
375
—
—
—
—
—
CEx.4
230
20
8.7
375
50
175
2/7
225
30.0
CEx.5
230
20
8.7
375
200
25
8/1
225
30.0
The fenders of the above Examples and Comparative Examples were subjected to the aforesaid compressive test. The results are shown in the graph of FIG. 14 .
As seen from FIG. 14, the fender 9 of Comparative Example 3 having a greater thickness of the first and second bumper members 91 , 92 than those of Comparative Example 1 had an increased percentage reaction force of 119% at Maximum Point A based on that of Comparative Example 1. It was found, however, that the fender 9 of Comparative Example 3 had a small compressibility of 53% representative of the distortion D. The following was found by continuing the observation of how the compressed fender was deformed. After buckling, the fender 9 of Comparative Example 3 assumed the position of FIG. 22B with a smaller distortion than Comparative Example 1 and the Examples to be described later, the position wherein the areas 92 b , 92 c above and below the buckling position BP on the inner periphery of the second bumper member 92 came into contact with each other. This was because, as mentioned supra, the second bumper member 92 was increased in thickness.
The fender 1 of Comparative Example 4 had the projection shifted downward relative to the buckling position BP, had a percentage reaction force of 102% at Maximum Point A based on that of Comparative Example 1, showing little increase in the reaction force. It was also found that the fender 1 of Comparative Example 4 had a small compressibility of 58% representative of the distortion D. The examination of a sectional shape of the buckled fender 1 of Comparative Example 4 revealed that the fender was buckled along the upper side of the projection 15 , as shown in FIG. 12 C.
The fender 1 of Comparative Example 5 had the projection shifted upward relative to the buckling position BP, had a percentage reaction force of 103% at Maximum Point A based on that of Comparative Example 1, showing little increase in the reaction force. It was also found that the fender 1 of Comparative Example 5 had a small compressibility of 58% representative of the distortion D. The examination of a sectional shape of the buckled fender 1 of Comparative Example 5 revealed that the fender was buckled along the lower side of the projection 15 , as shown in FIG. 13 C.
In contrast, the fenders 1 of Examples 5, 6 both trained increased percentage reaction forces of 110% t Maximum Point A based on that of Comparative Example 1. It was also found that both the fenders of these Examples had a great compressibility of 62% representative of the distortion D. The examination of sectional forms of the buckled fenders 1 of Examples 5, 6 revealed that the fenders assumed a buckled position, as shown in FIGS. 4C and 5C, respectively, wherein the second bumper member 12 buckled in a manner to clamp the projection 15 . The following was found by continuing the observation of how the compressed fender deformed. After buckling, the fenders 1 of these Examples assumed the respective positions shown in FIGS. 4C and 5C with a greater distortion D than the Comparative Examples because of the projection 15 clamped in the above manner, the position wherein the areas 12 b , 12 c above and below the projection 15 on the inner periphery of the second bumper member 12 came into contact with each other. The results are tabulated in Table 19.
TABLE 19
Increase of percentage
reaction force at Max. Point
Compressibility (%)
A (%) *2
representing distortion D
Ex. 5
110
62
Ex. 6
110
62
C. Ex. 1
100
60
C. Ex. 3
119
53
C. Ex. 4
102
58
C. Ex. 5
103
58
*1 percentage reaction force based on the reaction force of Comparative Example 1 (100%)
Example 7
The same rubber compound as in Example 5 and the following two reinforcement members were used to fabricate a circle-type fender 1 having a sectional shape shown in FIGS. 6A, 6 B as well as dimensions and an angle listed in Table 20. A projection 15 was of a trapezoidal shape in section, having dimensions listed in Table 21.
A reinforcement member in one end of the first bumper member 11 : a disk-like steel plate having a thickness of 28 mm and an outside diameter of 650 mm and including a through hole of inside diameter of 270 mm at its center; and
A reinforcement member in the flange 13 : the same steel plate as in Example 5
TABLE 20
T 1
220 mm
T 2
244 mm
T 1 /T 2
0.9
H 0
1000 mm
H 1
180 mm
H 2
820 mm
H 1 /H 0
0.18
θ 1
75.0°
D 1
680 mm
D 2
1500 mm
TABLE 21
H 3
410 mm
T 3
20 mm
T 3 /T 2 × 100
8.2%
W 1
100 mm
W 2
125 mm
W 3
50 mm
W 4
50 mm
W 1 /W 2
4/5
W 1 + W 2
225 mm
(W 1 + W 2 )/H 2 × 100
27.4%
Example 8
The same rubber compound and two reinforcement members as in Example 7 were used to fabricate a circle-type fender 1 having a sectional shape shown in FIGS. 15A, 15 B as well as dimensions and an angle listed in Table 22. A projection 15 was of a trapezoidal shape in section, having dimensions listed in Table 23.
TABLE 22
T 1
220 mm
T 2
244 mm
T 1 /T 2
0.9
H 0
1000 mm
H 1
230 mm
H 2
770 mm
H 1 /H 0
0.23
θ 1
75.0°
D 1
680 mm
D 2
1500 mm
TABLE 23
H 3
380 mm
T 3
20 mm
T 3 /T 2 × 100
8.2%
W 1
100 mm
W 2
125 mm
W 3
50 mm
W 4
50 mm
W 1 /W 2
4/5
W 1 + W 2
225 mm
(W 1 + W 2 )/H 2 × 100
29.2%
Example 9
The same rubber compound and two reinforcement members as in Example 7 were used to fabricate a circle-type fender 1 having a sectional shape shown in FIGS. 16A, 16 B as well as dimensions and an angle listed in Table 24. A projection 15 was of a trapezoidal shape in section, having dimensions listed in Table 25.
TABLE 24
T 1
220 mm
T 2
244 mm
T 1 /T 2
0.9
H 0
1000 mm
H 1
300 mm
H 2
700 mm
H 1 /H 0
0.30
θ 1
70.0°
D 1
680 mm
D 2
1500 mm
TABLE 25
H 3
350 mm
T 3
20 mm
T 3 /T 2 × 100
8.2%
W 1
100 mm
W 2
125 mm
W 3
50 mm
W 4
50 mm
W 1 /W 2
4/5
W 1 + W 2
225 mm
(W 1 + W 2 )/H 2 × 100
32.1%
Example 10
The same rubber compound and two reinforcement members as in Example 7 were used to fabricate a circle-type fender 1 having a sectional shape shown in FIGS. 17A, 17 B as well as dimensions and an angle listed in Table 26. A projection 15 was of a trapezoidal shape in section, having dimensions listed in Table 27.
TABLE 26
T 1
220 mm
T 2
244 mm
T 1 /T 2
0.9
H 0
1000 mm
H 1
100 mm
H 2
900 mm
H 1 /H 0
0.10
θ 1
80.0°
D 1
680 mm
D 2
1500 mm
TABLE 27
H 3
450 mm
T 3
20 mm
T 3 /T 2 × 100
8.2%
W 1
100 mm
W 2
125 mm
W 3
50 mm
W 4
50 mm
W 1 /W 2
4/5
W 1 + W 2
225 mm
(W 1 + W 2 )/H 2 × 100
25.0%
Comparative Example 6
The same rubber compound and two reinforcement members as in Example 7 were used to fabricate a circle-type fender 1 having a sectional shape shown in FIGS. 18A, 18 B as well as dimensions and an angle listed in Table 28. A projection 15 was of a trapezoidal shape in section, having dimensions listed in Table 29.
TABLE 28
T 1
220 mm
T 2
244 mm
T 1 /T 2
0.9
H 0
1000 mm
H 1
180 mm
H 2
820 mm
H 1 /H 0
0.18
θ 1
75.0°
D 1
680 mm
D 2
1500 mm
TABLE 29
H 3
410 mm
T 3
20 mm
T 3 /T 2 × 100
8.2%
W 1 ′
35 mm
W 2 ′
260 mm
W 3 ′
110 mm
W 4 ′
210 mm
The principal dimensions of the above Examples and Comparative Example are tabulated in Table 30.
TABLE 30
T 3 /T 2 ×
(W 1 + W 2 )/H 2 ×
T 1
T 2
T 3
T 1 /T 2
100
H 1
H 1 /H 0
H 3
W 1
W 2
W 1 /W 2
W 1 + W 2
100
Ex7
220
244
20
0.9
8.2
180
0.18
410
100
125
4/5
225
27.4
Ex8
220
244
20
0.9
8.2
230
0.23
380
100
125
4/5
225
29.2
Ex9
220
244
20
0.9
8.2
300
0.30
350
100
125
4/5
225
32.1
Ex10
220
244
20
0.9
8.2
100
0.10
450
100
125
4/5
225
25.0
CEx6
220
244
20
0.9
8.2
180
0.18
410
(35)
(260)
—
(225)
(27.4)
The fenders of the above Examples and Comparative Example were subjected to the aforesaid compressive test. The results are shown in the graph of FIG. 19 .
As seen from FIG. 19, the fender 1 of Comparative Example 6 had a small compressibility of 58% representative of the distortion D. The fender 1 of Comparative Example 6 had a percentage reaction force of 91% at Minimum Point C based on the reaction force at Maximum Point A, thus showing a small decline in the reaction force after buckling, i.e., after Maximum Point A.
In contrast, all the fenders 1 of Examples 7-10 were determined to have great comprehensibilities of 67 to 70% representative of the distortion D. The fenders 1 of Examples 7-10 had percentage reaction forces of 91 to 95% at Minimum Point C based on the reaction force at Maximum Point A, thus showing small declines in the reaction force after buckling, i.e., after Maximum Point A.
A comparison of the Examples showed that with increase in the ratio H 1 /H 0 and with decrease in the angle θ 1 the overall energy absorption tends to decline. On the other hand, as the ratio H 1 /H 2 decreases and the angle θ 1 increases, the constant load area for the first bumper member 11 becomes smaller. The results are tabulated in Table 31.
TABLE 31
Reaction force drop at Min.
Compressibility (%)
oint C (%) *1
representing distortion D
Ex. 7
93
70
Ex. 8
91
70
Ex. 9
94
63
Ex. 10
95
67
C. Ex. 6
91
58
*1 percentage reaction force based on the reaction force at Maximum Point A | A fender for absorbing the impact of a vessel is provided, which is formed of rubber and fixed to a fixing surface of a dock and adapted to have an impact receiving plate secured to a distal end of a body of the fender. The fender comprises a first bumper member having an elongated hollow cylindrical body of a constant outside diameter and affixed to the impact receiving plate at one end, and a second bumper member connected at one end to an opposite end of the cylindrical body of the first bumper member. The second bumper member at the opposite end thereof is fixed to the fixing surface at a portion having a hollow conical body with its distal end being greater in outside diameter than its closest end, and the second bumper member buckling radially outwardly upon receiving a compressive force from the vessel thereby absorbing the impact of the vessel; and a shoulder formed along an outer periphery of a connection portion between the first and second bumper members. | 4 |
The present invention relates to a solenoid valve, in particular, a valve plate for a solenoid valve.
BACKGROUND
Typically, solenoid valves are electromechanically operated valves having two main parts; the solenoid and the valve. The solenoid converts electro-magnetic energy into mechanical energy which, in turn, opens or closes the valve mechanically. Solenoid valves are used in a wide variety of applications, including in switchable valvetrains of internal combustion engines. Solenoid valves are disclosed in U.S. Pat. No. 7,137,411, and U.S. Pat. No. 6,367,434 wherein the solenoid valve comprises an electromagnet having a hollow cylindrical magnet housing, at least one coil winding and an armature, and a valve member having a hollow cylindrical valve housing for receiving a spool valve which is displaceable relative to the valve housing by the armature of the electromagnet.
So called “fast switching solenoids” operate by the same principle as solenoid valves generally. PCT application PCT/EP2012/062080 describes such a fast switching solenoid, comprising a magnetic coil surrounding an armature and magnetic core, the armature connected to a armature pin, extending through the magnetic core and attached to a valve body. A perforated housing member surrounds the valve assembly, the assembly comprising a valve spring, spring seat, valve body, valve plate on which the valve body seats and a spring retainer.
In fast switching solenoid valves, a seal can be used between the magnet core, valve body and the spring seat in order to ensure isolation between the high pressure chamber, around the periphery of the perforated housing, and middle pressure chamber, at the bottom of the valve, adjacent the spring retainer. Where misalignment occurs between the valve body and the valve plate in the housing, the seal can be compressed or permanently compacted during operation of the valve body during actuation. This seal may also contribute to increased friction of the system, depending on the temperature and pressure of the oil, negatively influencing switching performance of the valve.
The valve plate is typically pressed into the housing, requiring a tight tolerance between the valve plate and the housing and sorting of parts during assembly.
SUMMARY OF THE INVENTION
Certain terminology is used in the following description for convenience and descriptive purposes only, and is not intended to be limiting to the scope of the claims. The terminology includes the words specifically noted, derivatives thereof and words of similar import.
The present invention relates to a fast switching solenoid valve, and more particularly, to a free floating valve plate for a solenoid valve. Solenoid valves have a electromagnetic portion and a valve portion, the electromagnet having an electric plug contact, a housing, magnetic coil and armature. The valve portion having a pin associated with the armature, urging against a valve body, a valve plate and a perforate housing directing flow, as required.
The valve plate is axially retained within the housing, however, it is loosely fitted within the cylindrical portion of the housing, such that it self-aligns to the abutting valve body valve seat when the solenoid is actuated, correcting for any misalignments or tolerancing issues.
BRIEF DESCRIPTION OF DRAWINGS
The above mentioned and other features and advantages of the embodiments described herein, and the manner of attaining them, will become apparent and be better understood by reference to the following description of at least one example embodiment in conjunction with the accompanying drawings. A brief description of those drawings now follows.
FIG. 1 is a cross sectional view of a prior art solenoid valve.
FIG. 2 is a cross-sectional view of solenoid valve assembly according to one embodiment of the invention.
FIG. 3 is a cross sectional view of portion A of FIG. 2 .
FIG. 4 is a cross sectional perspective view of valve body and valve plate of FIG. 3 .
FIG. 5 is a perspective view of valve plate according to one embodiment of the invention.
FIG. 6 is a cross section view of solenoid valve assembly according to a second embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
Identically labeled elements appearing in different ones of the figures refer to the same elements but may not be referenced in the description for all figures. The exemplification set out herein illustrates at least one embodiment, in at least one form, and such exemplification is not to be construed as limiting the scope of the claims in any manner.
FIG. 1 is a cross sectional view of prior art solenoid 100 , comprising electric plug 119 , cylindrical magnet housing or yoke ring 101 and valve housing 102 assembled together, forming housing 103 . Magnetic coil 104 is nested on an inner circumferential surface of yoke ring 101 , in turn surrounding armature 105 , armature spring 106 , armature sleeve 107 , capped on a upper surface by damper 108 . Armature 105 is a hollow cylindrical structure, abutting hollow cylindrical magnet core 110 on a lower surface of armature 105 and an upper surface of magnet core 110 . Armature pin 109 inserted through the middle of armature 105 and extending through magnet core 110 , and into a center hole 111 of valve body 112 . Valve plate spring 113 surrounds the outer circumferential surface of valve body 112 , and is seated at an upper periphery against spring seat 114 , and a lower periphery on valve plate 115 . Seal ring 118 is nested between an upper surface of spring seat 114 , and a lower conical surface of magnet core 110 , sealing the interior cavity 120 formed by the center holes of magnet core 110 and valve body 112 , from an outer cavity 121 formed by the outer surface of valve body 112 and the inner surface of valve housing 102 . An upper portion of valve spring 117 is inserted into the cupped portion 122 of valve body 112 , supported laterally by inner side walls 123 of valve body 112 , and supported on a lower portion by spring retainer 116 .
In prior art solenoid 100 , valve plate 115 is press fit into inner cavity 125 of valve housing 102 , abutting valve housing shoulder 124 . This press fit may be accomplished by one of several methods, including, but, not limited to, sorting valve plates 115 to accommodate a measured dimension of cavity 125 , and precise machining of both cavity 125 and plate 115 prior to press fitting of plate 115 into cavity 125 . To compensate for any misalignment and resulting leakage of valve body 112 onto valve plate 115 , or valve body 112 in magnet core 110 , ring seal 118 is inserted between magnet core 110 , spring seat 114 and valve body 112 . Where there is a relatively large misalignment between valve body 112 and valve plate 115 , seal 118 may be pinched or compressed on one end, causing increased wear and may decrease durability of seal 118 .
FIG. 2 is a cross sectional side view of solenoid 1 according to one embodiment of the invention, comprising electric plug 15 , cylindrical magnet housing or yoke ring 2 and valve housing 3 assembled together, forming housing 4 . Magnetic coil 5 is nested in an inner circumferential surface of yoke ring 2 , in turn surrounding armature 6 , armature spring 7 , armature sleeve 8 , capped on a upper surface by damper 9 . Armature 6 is a hollow cylindrical structure, abutting hollow cylindrical magnet core 10 on a lower surface of armature 6 and an upper surface of magnet core 10 . Armature pin 11 inserted through the center of armature 6 and extending through magnet core 10 , and into a center hole 12 of valve body 13 . Alternatively, armature pin 11 may only come into contact with valve body 13 at a top surface of valve body 13 , as shown in FIG. 2 . Valve plate spring 14 surrounds the outer circumferential surface of valve body 13 , and is seated at an upper periphery against magnet core 10 , and at a lower periphery on valve plate retainer 19 . Valve plate retainer 19 is clipped or recessed into groove 21 in valve housing 3 , retaining free floating valve plate 20 between valve plate retainer 19 on an upper end and valve housing shoulder 22 on a lower end of valve plate 20 . An upper portion of valve spring 25 is inserted into cupped portion 26 of valve body 13 , supported laterally by inner side walls 27 of valve body 13 , and supported on a lower portion by spring retainer 28 .
In operation, in the embodiment shown, solenoid 1 is normally open, meaning that valve body 13 and valve plate 20 are separated by valve spring 25 acting to push valve body 13 upward. Alternatively, it is contemplated in the present invention that solenoid 1 can also be normally closed. In the activated mode shown in FIG. 2 , magnetic coil 5 is energized, creating a magnetic field causing armature 6 and armature pin 11 to move downwards against valve body 13 , compressing valve spring 25 and seating convex valve body seat 29 against and into concave valve plate seat 30 , thus stopping fluid flow from the direction of spring retainer 28 and inner cavity 32 into outer cavity 31 .
FIG. 3 is an enlarged cross sectional view of portion A of FIG. 2 . Yoke ring 2 , valve housing 3 , magnetic coil 5 , armature pin 11 , and magnet core 10 are as shown in FIG. 2 . For clarity, valve plate spring 14 is not shown in order to show perforations 33 in valve housing 3 , which in a normally open state would be in fluid communication with fluid from spring retainer 28 and inner cavity 32 . In this embodiment, valve plate retainer 19 is inserted into valve plate retainer groove 21 in housing 3 , retaining free floating valve plate 20 between retainer 19 and shoulder 22 . It is also contemplated in the present invention that other retention mechanisms can be used, including, but not limited to, the use of valve plate spring 14 and shoulder 22 and a valve plate 20 and retainer 19 being formed as one component.
Seating of convex valve body seat 29 into concave valve plate seat 30 are better shown in FIGS. 3 and 4 . In particular, FIG. 4 is a cross sectional perspective view of valve body 13 and valve plate 20 only, including valve body cupper portion 26 , convex valve body seat 29 and concave valve plate seat 30 .
FIG. 5 is a perspective view of valve plate 20 according to one embodiment of the invention. Valve plate 20 is a hollow cylindrical shape having a raised disk shape 35 , forming a shoulder 36 on which can be seated valve plate retainer 19 (see FIGS. 2 and 3 ) or valve plate spring 14 . toward the radial center of the raised disk 35 is concave valve plate seat 30 , to which convex valve body seat 29 can tightly abut and stop flow between the two surfaces. Circumferential outer surface 37 is dimensioned for any particular application such that plate 20 may freely float in valve housing 3 and remain seated on valve housing shoulder 22 .
As solenoid 1 is energized and valve body 13 is pushed downward by armature pin 11 , compressing valve spring 25 against spring retainer 28 , convex valve body seat 29 contacts at least a portion of valve plate seat 30 . As valve plate 20 moves freely laterally and is confined from movement upward or downward by shoulder 22 and retainer 19 and/or spring 14 so that no skewing occurs, valve plate 20 shifts laterally such that valve plate seat 30 aligns properly with valve body seat 29 , and the two surfaces are in continuous contact around their full circumference, this closing that fluid communication from inner cavity 32 to outer cavity 31 (see FIG. 3 ). In this embodiment gap seal 40 , which is the gap between valve body 13 and magnet core 10 , which restricts flow from outer cavity 31 (see FIG. 2 ), is elongated by lengthening magnet core extension 41 , providing further flow restriction.
FIG. 6 is a cross sectional view of solenoid 1 ′ according to a second embodiment of the invention. In this embodiment, the components similar to the embodiment described in FIG. 2 , including valve body 13 ′, valve plate 20 , magnet core 10 and armature pin 11 . In this embodiment, piston ring seal 45 is inserted into groove 46 on valve body 13 ′, providing additional sealing from outer cavity 31 . Piston ring seal 45 contacts an inner surface 47 of magnet core extension 41 . Alternatively, seal 45 can be inserted into a groove (not shown) on surface 47 in magnet core extension 41 , and seal 45 may contact an outer surface of valve body 13 ′.
In the foregoing description, example embodiments are described. The specification and drawings are accordingly to be regarded in an illustrative rather than in a restrictive sense. It will, however, be evident that various modifications and changes may be made thereto, without departing from the broader spirit and scope of the present invention.
In addition, it should be understood that the figures illustrated in the attachments, which highlight the functionality and advantages of the example embodiments, are presented for example purposes only. The architecture or construction of example embodiments described herein is sufficiently flexible and configurable, such that it may be utilized (and navigated) in ways other than that shown in the accompanying figures.
Although example embodiments have been described herein, many additional modifications and variations would be apparent to those skilled in the art. It is therefore to be understood that this invention may be practiced otherwise than as specifically described. Thus, the present example embodiments should be considered in all respects as illustrative and not restrictive.
LIST OF REFERENCE SYMBOLS
1 Solenoid
2 Yoke Ring or Magnet Housing
3 Valve Housing
4 Housing
5 Magnetic Coil
6 Armature
7 Armature Spring
8 Armature Sleeve
9 Damper
10 Magnet Core
11 Armature Pin
12 Valve Body Center Hole
13 Valve Body
14 Valve Plate Spring
15 Electric Plug
19 Valve Plate Retainer
20 Valve Plate
21 Valve Plate Retainer Groove
22 Valve Housing Shoulder
25 Valve Spring
26 Valve Body Cupped Portion
27 Valve Body Inner Side Walls
28 Spring Retainer
29 Valve Body Seat
30 Valve Plate Seat
31 Outer Cavity
32 Inner Cavity
33 Perforations
35 Valve Plate Disk
36 Valve Plate Shoulder
37 Valve Plate Circumferential Outer Surface
40 Gap Seal
41 Magnet Core Extension
45 Piston Ring Seal
46 Groove
47 Magnet Core Inner Surface
100 Solenoid
101 Yoke Ring or Magnet Housing
102 Valve Housing
103 Housing
104 Magnet Coil
105 Armature
106 Armature Spring
107 Armature Sleeve
108 Damper
109 Armature Pin
110 Magnet Core
111 Valve Body Center Hole
112 Valve Body
113 Valve Plate Spring
114 Spring Seat
115 Valve Plate
116 Spring Retainer
117 Valve Spring
118 Seal Ring
119 Electric Plug
120 Interior Cavity
121 Outer Cavity
122 Valve Body Cupped Portion
123 Valve Body Inner Side Walls
124 Valve Housing Shoulder
125 Valve Housing Inner Cavity | An electromagnetic hydraulic valve or solenoid having an electric plug, housing, magnetic coil, armature and armature pin, valve body and associated valve seat and valve plate and associated valve seat, the valve plate axially retained, but, freely floating laterally within the housing, such that the valve plate and valve plate seat is movable to align with the valve body and valve body seat. | 5 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] The present application claims priority to International Application No. PCT/KR2012/002000 filed Mar. 21, 2012, which claims priority to Korean Patent Application Nos. 10-2011-0024722 filed Mar. 21, 2011, 10-2011-0053352 filed Jun. 2, 2011, and 10-2011-0071361 filed Jul. 19, 2011, the entire contents of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] Aspects of the present invention relate to a device and method for controlling a floating structure of a solar power generating device, which can generate electricity from solar power of incident light while tracking the position of the sun in a state in which it floats on the water.
[0004] 2. Description of the Related Art
[0005] Recently, a floating structure equipped with a solar power generating device is operated to be floatable in reservoir or lake.
[0006] In general, a solar power generation method directly converts solar power into electrical energy by a solar cell. Differently from a solar heat generation method for generating energy using heat energy of sunlight, the solar power generation method generates electrical energy directly from sunlight by the solar cell formed of semiconductors.
[0007] In detail, the conventional solar power generating device includes a floating structure that is floatable on the water, a solar cell module installed on the floating structure, having a plurality of solar cells connected to each other and converting sunlight energy incident from the sun into electrical energy, and a floating structure rotating unit rotating the floating structure along the solar orbit.
[0008] With this configuration, since electricity generation efficiency of the solar cell module depends upon an incidence angle of sunlight, it is necessary to appropriately rotate the floating structure using the floating structure rotating unit according to the seasonal time zone.
[0009] The floating structure rotating unit is operated to control its rotation by cross-linking a pair of power units installed on the ground to both edges of the floating structure using a pair of wires and unwinding and winding of the wires. Since unwinding and wound amounts of the pair of wires cannot be precisely measured, it is difficult to accurately control the rotation of the floating structure.
[0010] The water level of the reservoir or lake may be changed by environmental factors. Accordingly, tension may be applied to the wires of the floating structure rotating unit. If the tension applied the wires exceeds a tensile strength, the wires may be broken. Thus, a change in the water level of the reservoir or lake may impair stability of the floating structure.
[0011] A conventional solar power generating device is configured such that a post is inserted to stand at the center of a floating structure to guide up-down movement of the floating structure while minimizing vibration or shock of the floating structure due to water conditions and the post is firmly supported by a separate support unit.
[0012] Therefore, the floating structure can stably rotate about the post along a predetermined track of sunlight. In a case where the floating structure rotating unit is damaged due to a big wave or wind, a rotation restraining state is released, so that an incidence angle with respect to the solar cell module may not be controlled and solar power generation may not be stably operated.
SUMMARY OF THE INVENTION
[0013] Aspects of the present invention provide a device and method for controlling a floating structure of a solar power generating device, which can precisely control rotation of the floating structure.
[0014] Other aspects of the present invention provide a device for controlling a floating structure, which can maintain stability even when a water level change occurs in the reservoir or lake.
[0015] Aspects of the present invention further provide a device for controlling a floating structure, which can temporarily support the floating structure when a floating structure rotating unit is damaged.
[0016] In accordance with one aspect of the present invention, there is provided a device for controlling a floating structure of a solar power generating device, the device including a floating structure ( 110 ) installed to be floatable on the water (W), a post ( 120 ) passing through the center of the floating structure ( 110 ) to then fixedly rise and inducing ascending and descending of the floating structure ( 110 ) according to the water level, a floating structure rotating unit ( 130 ) including a pair of first and second power devices ( 131 , 132 ) installed on the ground, and a pair of first and second wires ( 133 , 134 ) having both ends connected to the first and second power devices ( 131 , 132 ) and the floating structure ( 110 ) to cross each other, a wire winding measurement unit ( 140 ) fixedly installed on the ground to correspond to the first wire ( 133 ) and measuring a wound amount, and a control unit ( 150 ) connected to the wire winding measurement unit ( 140 ) and controlling forward and backward actuation of the pair of first and second power devices ( 131 , 132 ) according to the reference angle depending on the seasonal solar orbit.
[0017] The wire winding measurement unit ( 140 ) may include a fixing member ( 141 ) fixedly installed on the ground, an extending member ( 143 ) supported at one side of the fixing member ( 141 ) and extending in a lengthwise direction of the first wire ( 133 ), a plurality of rollers ( 145 ) installed at one side of the extending member ( 143 ) so as to allow the first wire ( 133 ) to be wound at a constant interval and rotatably installed according to winding of the first wire ( 133 ), and a sensor member ( 147 ) fixed at the other side of the extending member ( 143 ) and sensing the number of turns of one of the plurality of rollers ( 145 ).
[0018] The sensor member ( 147 ) may include a bar ( 147 a ) extending to the outside of the one of the plurality of rollers ( 145 ) and rotating in an interlocked manner, and a sensor ( 147 b ) installed at the other side of the extending member ( 143 ) so as to correspond to the bar ( 147 a ).
[0019] The sensor ( 147 b ) may be electrically connected to the control unit ( 150 ).
[0020] The device may further include a water level measurement unit ( 160 ) positioned in an internal space ( 122 ) of the post ( 120 ) and measuring the water level.
[0021] An air inlet hole ( 124 ) and a water inlet hole ( 126 ) may be formed in the post ( 120 ), the air inlet hole ( 124 ) formed at an upper portion of the post ( 120 ) and allowing the inflow of air into the internal space ( 122 ), and the water inlet hole ( 126 ) formed at a lower portion of the post ( 120 ) and allowing the inflow of water into the internal space ( 122 ).
[0022] The water level measurement unit ( 160 ) may include a buoyancy member ( 162 ) positioned on the surface of water induced into the internal space ( 122 ) of the post ( 120 ), and a distance measurement sensor ( 164 ) mounted in an internal space of the floating structure ( 110 ) and measuring the distance of the buoyancy member ( 162 ).
[0023] The device may further include a rotation preventing wire ( 170 ) having a center wound around either of top and bottom ends of the post ( 120 ) and both ends engaged with both sides of the floating structure ( 110 ).
[0024] Both ends of the rotation preventing wire ( 170 ) may be loosely installed such that rotation of the floating structure ( 110 ) is not interfered.
[0025] A wire fixing member ( 176 ) may be installed in the post ( 120 ), the wire fixing member ( 176 ) fixing a winding position of the rotation preventing wire ( 170 ).
[0026] In accordance with another aspect of the present invention, there is provided a method for controlling a floating structure of a solar power generating device, the method including a first step (S 10 ) of actuating first and second power devices ( 131 , 132 ) forward and backward, a third step (S 30 ) of measuring an rotation angle of the floating structure ( 110 ) based on an wound amount of the first wire ( 133 ), a fourth step (S 40 ) of comparing the measured rotation angle of the floating structure ( 110 ) with a reference angle input according to the seasonal solar orbit, and a fifth step (S 50 ) of fixing the floating structure ( 110 ) by stopping the actuating of the first and second power devices ( 131 , 132 ).
[0027] The method may further include a second step (S 20 ) of measuring a rotation time of a roller ( 145 ) having a bar ( 147 a ) installed therein when the first and second power devices ( 131 , 132 ) are actuated forward and backward.
[0028] As described above, in the device and method for controlling a floating structure of a solar power generating device, rotation of the floating structure can be accurately controlled according to the solar orbit.
[0029] In addition, the device for controlling a floating structure of a solar power generating device according to the present invention can maintain stability even when a water level change occurs in the reservoir or lake.
[0030] Further, the device for controlling a floating structure of a solar power generating device according to the present invention can temporarily support the floating structure in a safe manner even when the floating structure is uncontrollable by broken wires due to bad weather, thereby preventing a solar power generating device from being damaged and operating solar power generation in a stable manner.
[0031] Additional aspects and/or advantages of the invention will be set forth in part in the description which follows and, in part, will be obvious from the description, or may be learned by practice of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0032] The objects, features and advantages of the present invention will be more apparent from the following detailed description in conjunction with the accompanying drawings, in which:
[0033] FIG. 1 illustrates a floating structure controlling device according to an embodiment of the present invention;
[0034] FIG. 2 is an enlarged view illustrating one side of a wire winding measurement unit of FIG. 1 ;
[0035] FIG. 3 is a side view illustrating the other side of the wire winding measurement unit FIG. 2 ;
[0036] FIG. 4 is a flowchart illustrating a controlling method performed by a floating structure controlling device according to an embodiment of the present invention;
[0037] FIG. 5 is a laterally cross-sectional view of a floating structure controlling device according to another embodiment of the present invention;
[0038] FIG. 6 illustrates essential parts of FIG. 5 ;
[0039] FIG. 7 illustrates operating states of the floating structure shown in FIG. 5 ;
[0040] FIG. 8 is a laterally cross-sectional view of a floating structure controlling device according to still another embodiment of the present invention;
[0041] FIG. 9 illustrates a portion ‘A’ of FIG. 8 ;
[0042] FIG. 10 is an enlarged view of a wire fixing member of FIG. 9 ; and
[0043] FIG. 12 is a laterally cross-sectional view of a modified embodiment of the floating structure controlling device shown in FIG. 8 .
[0044] Hereinafter, a device for controlling a floating structure according to an embodiment of the present invention will be described in detail with reference to the accompanying drawings.
DETAILED DESCRIPTION OF THE INVENTION
[0045] Before the present invention is described terms or words used in the specification and claims of the present invention should not be restrictively construed as having the same meanings as those commonly used or those defined in dictionaries but should be interpreted as having meanings and concepts that are consistent with their meanings and concepts in the context of the spirit or scope of the present invention.
[0046] Therefore, the constitution shown in the embodiments and drawings of the present invention are provided only for illustration of the best exemplary embodiment of the present invention but are not provided to completely encompass the spirit or scope of the present invention. Accordingly, it is to be understood that various equivalents and modifications that can be substituted at the time of the filing date of the present application may be made to the invention.
[0047] As shown in FIG. 1 , the floating structure controlling device according to an embodiment of the present invention includes a floating structure 110 , a post 120 , a floating structure rotating unit 130 , a wire winding measurement unit 140 and a control unit 150 .
[0048] The floating structure 110 is formed using a material having buoyancy so as to be floatable on the water (W) and a through-hole 110 b may be formed at a predetermined position, preferably at the center of the floating structure 110 .
[0049] The floating structure 110 may take any shape so long as it has buoyancy without being limited to a particular shape. In the following description, the floating structure 110 will be described by way of example with regard to a case where the floating structure 110 is shaped of a rectangular plate.
[0050] A solar energy generating device 115 may be mounted on a top surface of the floating structure 110 . The solar energy generating device 115 may include a solar cell module, a power conversion device (not shown), and a storage battery (not shown).
[0051] The solar cell module is constituted of a plurality of solar cells connected to each other as a module and may be controlled by a support stand ( 117 of FIG. 5 ) capable of varying angles of the solar cell module to allow sunlight to be incident in a vertical direction.
[0052] The power conversion device is connected to the solar cell module and converts DC power into AC power, the DC power having the voltage and current generated by the solar cell module not constant.
[0053] The storage battery is connected to the power conversion device and is capable of accumulating electricity.
[0054] In addition, the floating structure 110 includes a slot hole 110 a having a predetermined section pierced such that a water surface and a bottom portion of the solar cell module make contact with each other. Low-temperature gas on the water surface is brought into contact with the heated bottom portion of the solar cell module by convection, thereby cooling the solar cell module.
[0055] The post 120 is disposed to stand and guides ascending and descending of the floating structure 110 according to the water level.
[0056] In particular, the post 120 penetrates the through-hole 110 b of the floating structure 110 and has one end fixed to the bottom of the reservoir or lake and the other end upwardly protruding from the floating structure 110 . Thus, a portion of the post 120 is positioned in water, that is, below the water surface, and the other portion of the post 120 is positioned outside the water.
[0057] Meanwhile, the floating structure rotating unit 130 includes a pair of first and second power devices 131 and 132 installed on the ground, and a pair of first and second wires 133 and 134 having opposite ends installed at the first and second power devices 131 and 132 and a fixing bar 116 of the floating structure 110 to be cross-linked with each other.
[0058] The pair of first and second power devices 131 and 132 may include a motor (not shown) generating power, a decelerator (not shown), a clutch (not shown) for transmitting or interrupting power of the motor, and a brake (not shown) stopping the motor.
[0059] The first power device 131 and the second power device 132 are actuated forward and backward, respectively, thereby rotating the floating structure 110 .
[0060] Meanwhile, as shown in FIGS. 2 and 3 , the wire winding measurement unit 140 is installed on the ground so as to correspond to the first wire 133 , and measures a wound amount on a real time basis.
[0061] The wire winding measurement unit 140 includes a fixing member 141 fixedly installed on a block structure B on the ground, an extending member 143 supported to one side of the fixing member 141 and extending in a lengthwise direction of the first wire 133 , a plurality of rollers 145 installed at one side of the extending member 143 to allow the first wire 133 to be wound in a constant interval and rotatably installed according to winding of the first wire 133 , and a sensor member 147 fixed at the other side of the extending member 143 and sensing the number of revolutions of one of the plurality of rollers 145 .
[0062] The fixing member 141 includes an ‘L’ shaped support unit 141 a and a standing unit 141 b upwardly installed on the support unit 141 a.
[0063] The extending member 143 is shaped of a rectangle having a predetermined length and fixedly installed at the standing unit 141 b.
[0064] The shape of the extending member 143 is not limited to the rectangle and various changes may be made to the shape of the extending member 143 so long as it can support the plurality of rollers 145 .
[0065] The plurality of rollers 145 are rotatably supported to a fixed shaft 143 a installed on a top surface of the extending member 143 to be spaced apart from each other in a lengthwise direction, and are arranged at different heights in a zigzag configuration, thereby establishing a winding state of the first wire 133 more firmly.
[0066] Here, the wound amount of the first wire 133 can be estimated per one revolution of the roller 145 .
[0067] The sensor member 147 includes a bar 147 a integrally extending to the outside of the one of the plurality of rollers 145 and rotating in an interlocked manner, and a sensor 147 b supported to a bracket 143 b installed at the other side of the extending member 143 and corresponding to the bar 147 a.
[0068] Here, the sensor 147 b may include one of known sensors, such as a proximity sensor or an optical sensor, and is electrically connected to the control unit 150 by a cable (C). For example, when a proximity sensor is used as the sensor 147 b , the bar 147 a is preferably made of a metal.
[0069] The control unit 150 is connected to the wire winding measurement unit 140 and the first and second power devices 131 and 132 and estimates a rotation angle of the floating structure 110 based on the number of revolutions of one of the plurality of rollers 145 having the bar 147 a installed therein. In addition, the control unit 150 controls forward and backward actuation of the pair of first and second power devices 131 and 132 in units of several seconds or several minutes according to reference angles pre-programmed by seasonal and temporal solar orbits.
[0070] Further, when the first and second power devices 131 and 132 are actuated forward and backward, the control unit 150 checks whether one of the plurality of rollers 145 having the bar 147 a installed therein rotates normally or not, thereby safely controlling the floating structure rotating unit 130 .
[0071] That is to say, a reference time, which can be compared with the rotation time of the one of the plurality of rollers 145 having the bar 147 a installed therein, is input to the control unit 150 . If the rotation time exceeds the reference time, it is determined that the one of the plurality of rollers 145 having the bar 147 a installed therein does not rotate normally, and the actuation of the first and second power devices 131 and 132 is forcibly stopped, thereby preventing over-rotation of the floating structure 110 .
[0072] Here, the control unit 150 may control a greater torque to be applied to the first power device 131 than to the second power device 132 to allow the second wire 134 to be unwound by the wound first wire 133 with a tension.
[0073] In addition, the floating structure 110 according to the present invention may further include a bearing 125 for rotatably supporting the floating structure 110 between the through-hole 110 b of the floating structure 110 and the circumferential surface of the post 120 .
[0074] In the embodiment of the present invention, an element for rotatably supporting the floating structure 110 is limited to the bearing 125 , but any element can be adopted so long as it can smoothly rotate the floating structure 110 with respect to the post 120 .
[0075] That is to say, the floating structure 110 includes gear teeth (not shown) formed on its outer peripheral surface, an interlocking gear (not shown) engaged with the gear teeth and a driving gear (not shown) engaged with the interlocking gear to increase a rotation torque by adjusting a gear ratio, thereby easily rotating the floating structure 110 .
[0076] Hereinafter, a method for controlling the floating structure according to an embodiment of the present invention will be described with reference to the accompanying drawings.
[0077] As shown in FIG. 4 , the floating structure controlling method according to an embodiment of the present invention includes a first step (S 10 ) of actuating first and second power devices 131 and 132 forward and backward in a predetermined time unit, a second step (S 20 ) of measuring a rotation time of a roller 145 having a bar 147 a installed therein when the first and second power devices 131 and 132 are actuated forward and backward, a third step (S 30 ) of measuring an rotation angle of the floating structure 110 based on an wound amount of the first wire 133 , a fourth step (S 40 ) of comparing the measured rotation angle of the floating structure 110 with a reference angle input according to the seasonal solar orbit, and a fifth step (S 50 ) of fixing the floating structure 110 by stopping the actuating of the first and second power devices 131 and 132 .
[0078] In the first step (S 10 ), motors of the first and second power devices 131 and 132 are actuated forward and backward for a predetermined time, that is, in units of several seconds or several minutes, to allow the solar energy generating device 115 to move along the solar orbit, thereby rotating the floating structure 110 .
[0079] That is to say, in order to rotate the floating structure 110 in a clockwise direction (the solar orbit) of FIG. 1 , the first wire 133 is wound by driving the motor of the first power device 131 while the second wire 134 is unwound by driving the motor of the second power device 132 .
[0080] In the second step (S 20 ), when the first and second power devices 131 and 132 are actuated forward and backward, a rotation time of one of the plurality of rollers 145 having a bar 147 a installed therein is measured using a sensor 147 b and is compared with a reference time input to the control unit 150 , thereby determining whether the one of the plurality of rollers 145 having the bar 147 a installed therein rotates normally or not.
[0081] If the rotation time of the one of the plurality of rollers 145 having the bar 147 a installed therein exceeds the reference time of the control unit 150 , it is determined that the one of the plurality of rollers 145 having the bar 147 a installed therein does not rotate normally. Therefore, the actuating of the first and second power devices 131 and 132 is forcibly stopped, the wire winding measurement unit 140 is checked and repaired, and the process goes back to the first step (S 10 ).
[0082] Next, in the third step (S 30 ), the wire winding measurement unit 140 estimates the wound amount of the first wire 133 based on the number of revolutions of the one of the plurality of rollers 145 having the bar 147 a installed therein, thereby measuring the rotation angle of the floating structure 110 on a real time basis.
[0083] In addition, in the fourth step (S 40 ), the control unit 150 receives the number of revolutions of the one of the plurality of rollers 145 and compares reference angles set according to seasonal and temporal solar orbits to control the motors of the first and second power devices 131 and 132 to be continuously actuated until the rotation angle of the floating structure 110 reaches a predetermined level.
[0084] That is to say, if the reference angle is 4°, the rotation angle of the floating structure 110 can be controlled based on the number of revolutions of the one of the plurality of rollers 145 having the bar 147 a installed therein.
[0085] If the rotation angle of the floating structure 110 is 2° per one revolution of the one of the plurality of rollers 145 , the motors of the first and second power devices 131 and 132 are continuously actuated until the one of the plurality of rollers 145 having the bar 147 a installed therein rotates twice.
[0086] Thereafter, if the number of revolutions of the one of the plurality of rollers 145 is 2, the actuating of the motors of the first and second power devices 131 and 132 is immediately stopped by a brake, thereby fixing the floating structure 110
[0087] The above-described process (the fourth and fifth steps) are repeatedly performed in units of several seconds or several minutes before the sunset, thereby accurately controlling the rotation of the floating structure 110 according to the solar orbit.
[0088] After the sunset, the motors of the first and second power devices 131 and 132 are actuated forward or backward which is opposite to that in the above actuation, thereby restoring the floating structure 110 to a morning start position.
[0089] Meanwhile, as shown in FIG. 5 , a floating structure controlling device according to another embodiment of the present invention further includes a water level measurement unit 160 .
[0090] Here, the post 120 has an internal space 122 and is shaped of a pillar having a laterally cross section corresponding to the through-hole 110 b to penetrate the through-hole 110 b of the floating structure 110 .
[0091] The post 120 may further include an air inlet hole 124 and a water inlet hole 126 .
[0092] The air inlet hole 124 is formed at an upper portion of the post 120 . That is to say, the air inlet hole 124 is positioned outside the reservoir or lake, to allow the air present outside the water to be induced into the internal space 122 .
[0093] The water inlet hole 126 is formed at a lower portion of the post 120 . That is to say, the water inlet hole 126 is positioned in water to allow water to be induced into the internal space 122 .
[0094] Therefore, the water level of the internal space 122 of the post 120 may be equal to the height of the reservoir or lake.
[0095] Referring to FIG. 6 , the water level measurement unit 160 is positioned in the internal space 122 of the post 120 and measures the water level of the reservoir or lake.
[0096] In more detail, the water level measurement unit 160 may include a buoyancy member 162 and a distance measurement sensor 164 .
[0097] The buoyancy member 162 is formed using a material having buoyancy and is positioned on a surface of the water induced into the internal space 122 of the post 120 . The buoyancy member 162 may take any shape so long as it is sized to be positioned within the internal space 122 .
[0098] The distance measurement sensor 164 is mounted in the internal space 122 of the post 120 , detects the buoyancy member 162 and measures a distance from the buoyancy member 162 to the distance measurement sensor.
[0099] In more detail, the distance measurement sensor 164 is mounted in the internal space 122 of the post 120 , specifically, above the buoyancy member 162 . That is to say, the distance measurement sensor 164 is mounted at a point spaced from the bottom surface of the reservoir or lake at a predetermined height, measures a distance between the distance measurement sensor and the buoyancy member 162 , and calculates a difference of the above distance, thereby measuring the water level of the reservoir or lake.
[0100] In addition, the distance measurement sensor 164 has a waterproofing function and is mounted under the buoyancy member 162 (that is, in water) if it can be operated in water, thereby measuring the water level by measuring the distance between the distance measurement sensor and the buoyancy member.
[0101] As described above, since the buoyancy member 162 and the distance measurement sensor 164 are positioned in the internal space 122 of the post 120 , the surface of the water induced into the internal space 122 is not affected by waves occurring on the water surface of the reservoir or lake.
[0102] That is to say, since the buoyancy member 162 is not subjected to up-down movement by the wave, the distance measurement sensor 164 can more accurately measure the distance from the buoyancy member 162 , thereby accurately measuring the water level of the reservoir or lake.
[0103] Hereinafter, a method for controlling a floating structure further including a water level measurement unit 160 according to the present invention will be described with reference to the accompanying drawings.
[0104] As shown in FIG. 7 , a control unit 150 determines a value measured by the water level measurement unit 160 and actuates first and second power devices 131 and 132 to adjust lengths of the first and second wires 133 and 134 .
[0105] That is to say, the control unit 150 is mounted at the reservoir or lake side to then be connected to a distance measurement sensor 164 to determine the measured value received from the distance measurement sensor 164 and controls the actuations of the first and second power devices 131 and 132 based on the determination result. The control unit 150 and the distance measurement sensor 164 may be connected to each other on line.
[0106] In detail, the floating structure 110 moves up and down according to a change in the water level of the reservoir or lake. Here, the first and second wires 133 and 134 connected to the floating structure 110 extend to generate tension (T), and if the generated tension exceeds a tensile strength of the first and second wires 133 and 134 , the first and second wires 133 and 134 may be broken.
[0107] Therefore, the control unit 150 receives data measured by the water level measurement unit 160 on line and compares the data with a value input to the control unit 150 for determination. In addition, the control unit 150 actuates the first and second power devices 131 and 132 to unwind the first and second wires 133 and 134 wound around a motor device 174 to maintain the tension to be lower than the tensile strength of the first and second wires 133 and 134 , thereby preventing the first and second wires 133 and 134 from being broken. In addition, the control unit 150 may be connected to the first and second power devices 131 and 132 by wires (not shown) for transmitting electrical signals.
[0108] Therefore, since the floating structure 110 is not affected by the wave formed in the reservoir or lake, the water level can be accurately measured, and based on the measured water level, lengths of the first and second wires 133 and 134 can be controlled according to the change in the water level of the reservoir or lake, thereby maintaining stability of the floating structure.
[0109] Meanwhile, as shown in FIG. 8 , the floating structure controlling device may further include a rotation preventing wire 170 .
[0110] The rotation preventing wire 170 is wound around one of top and bottom end of the post 120 (the bottom end in this embodiment) and the both ends are engaged with a connecting member 175 of the floating structure 110 .
[0111] Preferably, the both ends of the rotation preventing wire 170 are loosely installed such that rotation of the floating structure 110 is not interfered.
[0112] Here, as shown in FIG. 9 , in order to fix a winding position of the center of the rotation preventing wire 170 , at least one wire fixing member 176 may further be fixedly installed at the post 120 .
[0113] As shown in FIG. 10 , the wire fixing member 176 has a ‘U’ shaped cross section. In a case where both ends of the wire fixing member 176 are fixed, a space is formed in the wire fixing member 176 .
[0114] Therefore, the rotation preventing wire 170 passes the space of the wire fixing member 176 and placed to enable a central winding portion of the rotation preventing wire fixed on a point of the floating structure 110 to be to be safely maintained.
[0115] Here, the same rotation preventing effect can be achieved such that a pair of wire fixing members 176 are fixedly installed on the post 120 in a connecting loop (not shown), one end of the rotation preventing wires 170 is connected to the connecting loop and the other end of the rotation preventing wire 170 is cross-linked to the connecting member 175 of the floating structure 110 .
[0116] In addition, as shown in FIG. 11 , the same rotation preventing effect can also be achieved such that a pair of ground fixing members 177 , instead of the wire fixing member 176 or the connecting loop, are separately installed provided on the bottom of a water depth, one ends of the pair of rotation preventing wires 170 are connected to each other and the other ends of the rotation preventing wires 170 are cross-linked to the connecting member 175 of the floating structure 110 .
[0117] In this case, both ends of the rotation preventing wire 170 may be loosely installed such that rotation of the floating structure 110 is not interfered. In particular, the post 120 and the pair of ground fixing members 177 are preferably arranged on a line.
[0118] Here, the same effect can be expected even when both ends of the ground fixing member 177 are loosely installed on the ground to be positioned in the same line with the post 120 , rather than on the bottom of the water depth, such that the rotation of the floating structure 110 is not interfered.
[0119] Hereinafter, a method for controlling a floating structure further including a rotation preventing wire 170 according to the present invention will be described with reference to the accompanying drawings.
[0120] In a case where there is a big wave or wind due to an aggravating water environment, first and second wires 133 and 134 of a floating structure rotating unit 130 may be broken.
[0121] In such a case, a rotation restraining state in which a floating structure 110 is restrained by the first and second wires 133 and 134 may be released. As the result, an incidence angle with respect to a solar cell module may not be controlled, solar power generation may not be stably operated, and concerns of major facilities being damaged may be raised.
[0122] In this case, the floating structure 110 rotates in an uncontrollable manner in one direction by the wind and wave. Here, the rotation preventing wire 170 having both ends thereof loosely installed at both sides of the floating structure 110 is tightened to restrain rotation of the floating structure 110 , thereby temporarily supporting the floating structure 110 in an emergent situation in which the first and second wires 133 and 134 of the floating structure rotating unit 130 are broken.
[0123] Therefore, even when the floating structure 110 is uncontrollable by the broken first and second wires 133 and 134 due to bad weather, the floating structure 110 can be temporarily supported in a safe manner, thereby preventing a solar power generating device and operating solar power generation in a stable manner after repairing an actuating member.
[0124] Although exemplary embodiments of the present invention have been described in detail hereinabove, it should be understood that many variations and modifications of the basic inventive concept herein described, which may appear to those skilled in the art, will still fall within the spirit and scope of the exemplary embodiments of the present invention as defined by the appended claims. | Aspects of the present invention relate to a device and method for controlling a floating structure of a solar power generating device, which can generate electricity from solar power of incident light while tracking the position of the sun in a state in which it floats on the water. | 7 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of application Ser. No. 09/451,719, the entire disclosure of which is hereby incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] This invention relates to nuclear magnetic resonance imaging (MRI) and, more particularly, to extended-linear polymeric contrast agents for magnetic resonance imaging of tumors and methods of synthesizing such agents.
[0003] Tumor angiogenesis is the recruitment of new blood vessels by a growing tumor from existing neighboring vessels. This recruitment of new microvasculature is a central process in tumor growth and in the potential for aggressive spreading of the tumor through metastasis. All solid tumors require angiogenesis for growth and metastasis. Thus, the level of angiogenesis is thought to be an important parameter for the staging of tumors. Furthermore, new therapies are being developed which attack the process of angiogenesis for the purpose of attempting to control tumor growth and tumor spread by restricting or eliminating the tumor blood supply. It is therefore of clinical importance to be able to monitor angiogenesis in tumors in a noninvasive manner.
[0004] To assess angiogenic activity of tumors, two parameters are of primary importance: vascular volume and vascular permeability. Invasive techniques utilizing tissue staining can be used to assess microvascular development, but the sensitivity of existing staining methods is not high enough and the prognostic value of such methods is not yet well established (N. Weidner, et al., New Eng. J. Med. 324:1-8, 1991). At present there is no single imaging method capable of providing quantitative characterization of tumor angiogenesis.
[0005] As for non-invasive methods for assessing the two parameters, the parent application Ser. No. 09/451,719 teaches a magnetic resonance imaging method with a type of contrast agent that enables measurement of both vascular volume and vascular permeability with much higher sensitivity than heretofore possible. Such measurement should facilitate independent prognostic assessments of cancer and help in monitoring cancer therapy non-invasively.
[0006] When a substance such as living tissue is subjected to a uniform magnetic field (polarizing field B 0 ), individual magnetic moments of the nuclear spins in the tissue attempt to align with this polarizing field along the z axis of a Cartesian coordinate system, but process about the z axis direction in random order at their characteristic Larmor frequency. If the substance, or tissue, is subjected to a magnetic field (excitation field B 1 ) which is in the x-y plane and at a frequency near the Larmor frequency, the net aligned longitudinal magnetization may be rotated, or “tipped”, into the x-y plane to produce a net transverse magnetization. A signal is emitted by the excited spins after the excitation signal B 1 is terminated. This NMR signal may be received and processed to form an image.
[0007] When utilizing NMR signals of this type to produce images, magnetic field gradients (G X G Y and G Z ) are employed. Typically, the region to be imaged is scanned with a series of measurement cycles in which these gradients vary according to the particular localization method being used. The resulting set of received NMR signals is digitized and processed to reconstruct the image using one of many well known reconstruction techniques.
[0008] One of the mechanisms employed in MRI to provide contrast in reconstructed images is the T 1 relaxation time of the spins. After excitation, a period of time is required for the longitudinal magnetization to fully recover. This period, referred to as the T 1 relaxation time, varies in length depending on the particular spin species being imaged. Spin magnetizations with shorter T 1 relaxation times appear brighter in MR images acquired using fast, T 1 weighted NMR measurement cycles. A number of contrast agents which reduce the T 1 relaxation time of neighboring water protons are used as in vivo markers in MR images. The level of signal brightness, i.e., signal enhancement, in T 1 weighted images is proportional to the concentration of the agents in the tissue being observed.
[0009] In pre-clinical research applications, high-field MRI has been used to assess tumor volume and tumor signal changes in animal models after treatment with tamoxifen, a type of antiangiogenic agent (H. E. Maretzek, et al., Cancer Res., 54:5511-5514, 1994). By using an intravascular contrast agent, albumin-Gd—DTPA, tumor vascular volume and permeability were measured as well as spatial distribution of the neovasculature. In another study using a high polarizing field, tumor growth was followed by using a variety of NMR measurement pulse sequences that allowed the investigators to distinguish microvessels from larger vessels through blood oxygen level dependent effects. Permeability was assessed by noting the time dependent changes in NMR signal when Gd—DTPA was administered to the animal (R. Abramovitch, et al., Cancer Res. 55:1956-1962, 1995).
[0010] At lower polarizing fields that are available at clinical sites, Gd—DTPA, an NRI contrast agent approved by the FDA (U.S. Food and Drug Administration) has been used to estimate angiogenic activity of tumors (C. Frouge, et al., Invest. Radiol. 29:1043-1049, 1994). However, this contrast agent is not ideal for characterizing tumor vasculature because it rapidly migrates to the extravascular space before being excreted through the kidneys. The tumor NMR signal measurements become delicate, being based on the dynamics of contrast agent uptake and elimination. Staging of tumors by this approach has been difficult (R. Brasch, et al., Radiology 200:639-649, 1996).
[0011] To avoid the delicate dynamic aspects of Gd—DTPA uptake measurements, others have used a macromolecular contrast agent, albumin-Gd—DTPA (F. Demser, et al., Mag. Res. Med. 37:236-242, 1997). In this instance, the elimination process does not play a role in the observed MR signals, so that a much simpler and more reliable signal analysis is possible. Thus, MR signals based on T 1 changes (proportional to agent concentration) have provided indications of tumor blood vessel leak rate and tumor blood volume. This then represents an effective imaging method for assessing tumor angiogenesis. A severe drawback to this approach, however, is that this macromolecular agent has associated immune reactions when injected and leads to substantial toxicities. Thus, at present, this contrast agent is unsuitable for clinical applications (T. J. Passe, et al., Radiology 230:593-600, 1997).
BRIEF SUMMARY OF THE INVENTION
[0012] In a preferred embodiment of the invention, a contrast agent for use in acquiring MRI images for the purpose of assessing tumor angiogenesis comprises a reptating polymer containing gadolinium. Methods for synthesizing this polymer and linear extended polymeric paramagnetic chelates for use as MRI contrast agents are provided wherein DTPA (diethylaminetriaminepentaacetic acid) chelator moieties are conjugated to higher than 90% of the monomer residues of the polyamino acid backbone chain. The resulting polymer can be labeled with Gd, since each chelator moiety will hold a Gd ion, and the resulting conformation is of an unfolded, extended linear type, capable of entering small pores and moving around obstacles in the extracellular space of living tissues. Efficient production of these extended polymers is critical for the application of such contrast agents to medical imaging.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] [0013]FIG. 1 is a block diagram of an MRI system which employs contrast agents of the present invention;
[0014] [0014]FIG. 2 is a graphic representation of a pulse sequence performed by the MRI system of FIG. 1 to assess tumor angiogenosis; and
[0015] [0015]FIG. 3 is a graphic representation of the relationship between proton relaxivity and lysine content for linear extended polymeric paramagnetic chelates usable as MRI contrast agents.
DETAILED DESCRIPTION OF THE INVENTION
[0016] In characterizing tumor angiogenesis, a contrast agent comprising a reptating polymer is intravenously injected and a series of timed medical images is obtained. A signal enhancement (in T 1 weighted images) above a certain threshold, preferably 10%, constitutes an indicator of angiogenic activity. Signals beyond the threshold level will indicate increased angiogenic activity in the form of increased microvascular density, usually at the periphery edges of the tumor, and increased vascular permeability at the periphery and throughout the interior of the tumor.
[0017] One contrast agent for characterizing tumor angiogenesis is a reptating polymer, preferably as described in Uzgiris U.S. Pat. No. 5,762,909, issued Jun. 9, 1998 and assigned to the instant assignee. U.S. Pat. No. 5,762,909, incorporated by reference herein, describes the creation of elongated, worm-like macromolecules. A particularly preferred polymer is a homopolymer of lysine where the lysine residues are substituted with Gd—DTPA, or gadolinuim- diethylentriaminepentaaceticacid. The degree of substitution must be very high, in excess of 90%, for the polymer to assume an elongated worm-chain conformation. The polymers described in U.S. Pat. No. 5,762,909 have such a conformation as determined by their measured persistence length (in the range of 100 to 600 Å) which is similar to the persistence length of double-stranded DNA. Double-stranded DNA is a classic reptating polymer and is separated according to length in gel electrophoresis by the mechanism of reptation (R. H. Austin, et al., Physics Today, pp. 32-37, 1997). The polymers of U.S. Pat. No. 5,762,909 remain in the vasculature as a blood pool agent and leak out of the endothelium only in tumors which have a hyperpermeable endothelium. The hyperpermeability is a result of angiogenesis signals emanating from tumor cells under nutrient and oxygen stress. The polymers are shown to be ideal agents for MR imaging methods to measure tumor blood volume and tumor endothelium permeability. The polymers for use in characterizing tumor angiogenesis are made by substituting the lysine residues of polylysine with DTPA in a mixed anhydride reaction (Sieving, et al. Bioconjugate Chem. 1:65-71, 1990). However, in order to attain the reptating conformation, the anhydride reaction and the coupling reaction are modified: the synthesis of the anhydride of DTPA is as previously described by Sieving, but the reaction is preferably run between −25° C. and −28° C. for 30 minutes under dry nitrogen atmosphere. The coupling of the anhydride to the lysines is modified in that a much higher molar ratio of anhydride to lysines residues is used in the coupling (from 7 to 10). After the coupling reaction, the reaction solution is subject to roto-vaporation at 50° C. to release all the volatile organic molecules and then the product is purified through extensive dia-filtration (Amicon, 10 kD molecular weight cutoff filters). To achieve the final MR active agent, the paramagnetic ion gadolinium is incorporated into the product polymer chelating DTPA groups by dropwise addition of GdCl 3 in 0.1 M HCl (50 mM in Gd) into the polymer solution (15 mM NaHCO 3 ). The dropwise addition of Gd continues until a slight indication of free Gd (not chelated by available DTPA groups) is noted (small aliquots of polymer solution added to 10 μM of arzenzo III in acetate buffer-free Gd turns the dye solution blue). The reptating polymer is then introduced into a blood vessel of the subject.
[0018] Other paramagnetic ions besides Gd may be used. However, Gd is the most paramagnetic (i.e., has the most unpaired electrons) and thus is the most effective as contrast agent. A chelator such as DTPA must be used because free Gd is toxic. The chelator folds around the Gd and tightly binds it, but the water protons can come into one Gd coordination site and be relaxed.
[0019] A comparable Lanthanide series element that can be used is Dy, dysprosium. All other elements are less effective in relaxing water protons. Iron and manganese (MN(II) and Fe(III) have also been used with much less relaxivity per ion by a factor of about 3 for the DTPA chelate.
[0020] The uptake of these molecules, as judged by MR signal enhancements, is more than ten times higher than observed for other macromolecular agents such as compact coiled peptide agents or globular protein, albumin-Gd—DTPA, agents. The extravasation of the polymeric agents in the tumors is thought to be much higher than for the globular agents due to the process of reptation, which allows the polymers to migrate around obstacles in a small convective force field. The globular agents, on the other hand, cannot move through very small pores or around obstacles in a fibrous matrix of the basement membrane of the endothelium and are thus repelled and mostly remain in the blood circulation before being cleared out through the renal or hepatobiliary excretion channels. Hence, globular agents give small tumor signals and small signals of tumor permeability when injected intravenously.
[0021] If a relatively short chain length polymeric agent (typically about 150-250 monomers or residues) is used, the signal will be reduced from a longer chain of about 500 residues by perhaps a factor of 4 for well-known reasons having to do with circulation times and the physics of the reptation process. However, the signal response will be faster and the faster blood clearance will be a desirable feature for monitoring and following effects of antiangiogenesis therapy.
[0022] Reptating polymers as taught in the parent application Ser. No. 09/451,719 are synthesized either from a homopolymer such as polylysine or from random co-polymers of glutamic acid and lysine. The random co-polymers are more suitable for synthesis of short chain agents and allow for a more robust synthesis procedure.
[0023] In order to assess tumor angiogenesis in accordance with an embodiment of the parent application Ser. No. 09/451,719, a subject is first imaged and then the contrast agent is introduced into the subject by injecting the contrast agent intravenously at approximately 0.025 moles Gd/Kg. The subject is then imaged again, preferably beginning immediately after injection and at certain timed intervals. Preferably, the timed intervals are shortly after injection (within 10 minutes) and up to 1 hour post injection. For highest sensitivity of permeability, an image at 24 hours may also be acquired. FIGS. 1 and 2, as described below, illustrate a preferred MRI imaging procedure. To determine changes in blood volume, imaging should take place within 10 minutes of contrast agent injection.
[0024] [0024]FIG. 1 shows the major components of a preferred MRI system which can be used in practicing the invention. Operation of the system is controlled from an operator console 100 which includes a keyboard and control panel 102 and a display 104 . Console 100 communicates through a link 116 with a separate computer system 107 that enables an operator to control the production and display of images on the screen of display 104 . Computer system 107 includes a number of modules which communicate with each other through a backplane 120 . These include an image processor module 106 , a central processing unit (CPU) module 108 and a memory module 113 , known in the art as a frame buffer for storing image data arrays. Computer system 107 is linked to a disk storage 111 and a tape drive 112 for storage of image data and programs, and communicates with a separate system control 122 through a high speed serial link 115 .
[0025] System control 122 includes a set of modules connected together by a backplane 118 . These include a CPU module 119 and a pulse generator module 121 which is coupled to operator console 100 through a serial link 125 . Through link 125 , system control 122 receives commands from the operator which determine the scan sequence that is to be performed.
[0026] Pulse generator module 121 operates the system components to carry out the desired scan sequence, and produces data which determine the timing, strength and shape of the RF pulses to be produced, and the timing and length of the data acquisition window. Pulse generator module 121 is coupled to a set of gradient amplifiers 127 , to determine the timing and shape of the gradient pulses to be produced during the scan. Pulse generator module 121 also receives patient data from a physiological acquisition controller 129 that receives signals from a number of different sensors attached to the patient, such as electrocardiogram (ECG) signals from electrodes or respiratory signals from a bellows. Pulse generator module 121 is also coupled to a scan room interface circuit 133 which receives signals from various sensors associated with the condition of the patient and the magnet system. Through scan room interface circuit 133 , a patient positioning system 134 receives commands to move the patient to the desired position for the scan.
[0027] Gradient amplifier system 127 that receives gradient waveforms from pulse generator module 121 is comprised of G X , G Y and G Z amplifiers. Each gradient amplifier excites a corresponding gradient coil in an assembly 139 to produce the magnetic field gradients used for position encoding acquired signals. Gradient coil assembly 139 forms part of a magnet assembly 141 which includes a polarizing magnet 140 and a whole-body RF coil 152 . A transceiver module 150 in system control 122 produces pulses which are amplified by an RF amplifier 151 and coupled to RF coil 152 by a transmit/receive switch 154 . The resulting signals radiated by the excited nuclei in the patient may be sensed by the same RF coil 152 and coupled through transmit/receive switch 154 to a preamplifier 153 . The amplified NMR signals are demodulated, filtered, and digitized in the receiver section of the transceiver 150 . Transmit/receive switch 154 is controlled by a signal from pulse generator module 121 to electrically connect RF amplifier 151 to coil 152 during the transmit mode and to connect preamplifier 153 to coil 152 during the receive mode. Transmit/receive switch 154 also enables a separate RF coil (for example, a head coil or surface coil) to be used in either the transmit or receive mode.
[0028] The NMR signals picked up by RF coil 152 are digitized by transceiver module 150 and transferred to a memory module 160 in system control 122 . When the scan is completed and an entire array of data has been acquired in memory module 160 , an array processor 161 operates to Fourier transform the data into an array of image data. These image data are conveyed through serial link 115 to computer system 107 where they are stored in disk storage 111 . In response to commands received from operator console 100 , these image data may be archived on tape drive 112 , or may be further processed by image processor 106 and conveyed to operator console 100 for presentation on display 104 .
[0029] Although the invention can be used with a number of different pulse sequences, a preferred embodiment of the invention employs a fast 3D (three dimensional) rf (radio frequency) phase spoiled gradient recalled echo pulse sequence, depicted in FIG. 2, to acquire the NMR image data. The pulse sequence “3dfgre” available on the General Electric 1.5 Tesla MR scanner sold by General Electric Company, Milwaukee, Wis., under the trademark “SIGNA” with revision level 5.5 system software is used.
[0030] As shown in FIG. 2, an RF excitation pulse 220 having a flip angle of from 40° to 60° is produced in the presence of a slab select gradient pulse 222 to produce transverse magnetization in the three-dimensional (3D) volume of interest as taught in Edelstein et al. U.S. Pat. No. 4,431,968, issued Feb. 14, 1984 and assigned to the instant assignee. This is followed by a slice encoding gradient pulse 224 directed along the z axis and a phase encoding gradient pulse 226 directed along the y axis. A readout gradient pulse 228 directed along the x axis follows, and a partial echo (60%) NMR signal 230 is acquired and digitized as described above. After the acquisition, rewinder gradient pulses 232 and 234 rephase the magnetization before the pulse sequence is repeated as taught in Glover et al. U.S. Pat. No. 4,665,365, issued May 12, 1987 and assigned to the instant assignee. As is well known in the art, the pulse sequence is repeated and the respective slice and phase encoding gradient pulses 224 and 226 are stepped through a series of values to sample the 3D k-space.
[0031] The acquired 3D k-space data set is Fourier transformed along all three axes and a magnitude image is produced in which the brightness of each image pixel indicates the NMR signal strength from each corresponding voxel in the 3D volume of interest.
[0032] An initial signal is then compared with the signal enhancement observed at selected times, preferably a short time after injection (within 10 minutes) and then at several time points up to 60 minutes post injection. For highest sensitivity to measure endothelial permeability of the tumor, a subsequent image at about 24 hours may also be taken. The initial image after injection (within 10 minutes) provides a measure of tumor blood volume or microvascular density, for each pixel of the image. Subsequent images then establish the rate of leakage into the tumor interstitium, again on a pixel by pixel basis. Maps of blood volume and of endothelium permeability may then be generated and displayed as an image or overlaid on the MR image directly. Both anatomical and physiological features will then be displayed simultaneously, giving radiologists not only the level of angiogenesis as an average quantity but also its activity as a function of position, a very desirable feature for staging and prognosis.
[0033] Signal enhancements at the endpoint of about 24 hours, that are below some threshold value, preferably about 10% (for the canonical dose of 0.025 mmoles Gd/Kg), signify minimal angiogenesis activity, as the examples given below imply. Higher signal values (preferably 75%, most preferably 90%) imply ever increasing angiogenic activity. The endpoint signals at 24 hours are due to capillary leakage, as blood concentration levels at that time will be negligibly small for the reptating polymer contrast agents described in the parent application Ser. No. 09/451,719 (although this would not be true for globular protein agents whose blood circulation time constant may be 24 hours and longer). In growing tumors, the endpoint signals may be expected to be as high as 200% in peripheral regions where neovasculature development is at its highest during angiogenesis.
[0034] The reptating polymer contrast agent confers a number of advantages over previous methods that involved the use of small extracellular agents or large macromolecular agents.
[0035] First, the polymeric agent does not leave the tumor at an appreciable rate over many hours, thus simplifying the uptake dynamics upon which the assay for angiogenesis is based.
[0036] Second, the signal changes observed with the reptating polymer agent are approximately 10 times higher than observed with an albumin agent or with the extracellular agent Gd—DTPA. Thus, this reptating polymer contrast agent provides a much higher sensitivity to changes in tumor permeability and yields significant changes in signal over the entire tumor volume unlike what is observed for the albumin agents.
[0037] Third, vascular permeability probed with a reptating polymer may be qualitatively different from that probed with a large globular protein such as albumin: the endothelial layer structures that result in the observed leakage in these two instances may be different. In the latter instance, a fragmentation of the basement membrane is required as well as existence of loose endothelial cell junctions for the albumin to be transported out of the vasculature. For reptating polymers, the junctions may be tighter, the basement membrane may not need to be as fragmented, or there may be specific transport mechanisms involving transendothelial transport. For example, in the tumor stroma, considerable levels of fibrinogen are found. This plasma protein has a long, extended conformation and high negative charge. The accumulation of fibrinogen in tumors appears to be associated with angiogenesis and is necessary for conversion of the extracellular matrix into a form conducive to cell growth. Thus, the uptake of the reptating polymer (which is also of high negative charge and is extended in form) may mimic the natural transport processes associated with angiogenesis much more closely than will the uptake of globular proteins.
[0038] Fourth, as observed by MRI signal changes, there appears to be little accumulation of the polymeric agent in organs such as liver, kidney or muscle. The clearance of the agent from these organs appears to follow the blood circulation decay rate and no trapping or prolonged binding is evident in these tissues. Furthermore, the blood circulation times can be adjusted by varying the polymer length. For short polymers (of 140-150 residues) the circulation time constant can be as short as 15 minutes (equal to the circulation time of the extracellular agent, Gd—DTPA). Thus, at present, there are no indications that toxicity will become an issue with these types of agents.
[0039] In addition to MRI, it is also possible to use nuclear imaging techniques with the polymeric agents. Presently the Gd is chelated in the DTPA polymer chain. It is possible to incorporate, for example, technetium-99 as well as the Gd in such a polymer. The agent uptake will still occur by the reptation mechanism. However, the imaging would be made in this instance through nuclear gamma radiation detection. This can be an alternative to the technetium-99 technique for angiogenesis evaluation with the advantages of a higher uptake of the reptating polymer agent.
[0040] It has been shown that linear extended polymeric contrast agents of suitable cross section are capable of enhancing the MRI contrast of tumors to a much larger extent than clinical extracellular agents or large globular agents such as labeled protein agents (U.S. Pat. No. 5,762,909; E. E. Usgiris, ISRM Proc. 1998, p. 1656). The synthesis of such agents has been described previously and relied on methods developed earlier by Sieving et al. ( Bioconjugate Chem. 1:65-71, 1990). However, the synthesis procedure involving the anhydride method as delineated by Sieving does not provide the desired high conjugation efficiency necessary to achieve an elongated state.
[0041] The anhydride method involves conversion of the chelator molecule DTPA to an anhydride which then can react with an amine group of the lysines of a polylysine amino acid chain. The product polymer is thus a chain in which lysine groups are conjugated with DTPA. The usual degree of conjugation achieved was about 85%, and only rarely did the conjugation reach into the 90% range. Yet such high conjugation is necessary for the linear extended conformation to be achieved. The reaction was not well enough understood to predict what to change in the procedures to achieve a higher degree of conjugation. For example, a change in the anhydride to lysine molar ratio to higher values, a natural adjustment to favor higher lysine substitution, did not yield reliable improvements in the conjugation efficiency. The generation of the anhydride and the coupling reaction to polylysine, each follow complex kinetics and it was not obvious whether efficiency higher than 85% could be achieved consistently in this reaction scheme (particularly for longer chains which may have more propensity to physically sequester residual free lysine groups during the reaction).
[0042] A surrogate marker for conformation is the proton relaxivity of the polymer agent. If the agent is in a tightly coiled state, steric hindrance prevents free rotation of DTPA around the epsilon bond to the peptide backbone. If rotation is hindered, the relaxivity is increased owing to the longer rotational correlation time of the agent - relaxation of water protons becomes more effective (R. B. Lauffer, Chem. Rev. 87:901, 1987). Conversely, if the correlation time is shortened the water proton relaxation rate decreases. This can result if the rotation around the epsilon bonds of each DTPA is allowed, as would happen if the polymer backbone is fully extended and the invidividual DTPA moieties are not sterically restricted. This effect has been observed for example when the first few exposed lysine groups of the protein albumin are conjugated with DTPA (M. Spanoghe et al., Magn. Reson. Imaging 10:913, 1992).
[0043] [0043]FIG. 3 shows the relationship of proton relaxivity to free lysine content of the linear extended polymeric agents. As the lysine content is decreased below 20%, the polymer chain becomes less and less folded. The chain is fully extended, with relaxivity at a minimum plateau, for lysine content below about 7-10%. Likewise, as the lysine content increases beyond 20%, an upper plateau of about 10 to 11 relaxivity units is reached, indicating that the propensity to fold up into a coiled state is driven by the lysine content of the chain as it increases from below 10% to higher values. The folding conformation must be driven in part by ionic charge interactions between positive lysine groups and negatively charged DTPA groups, and will lead to tightest folding when there are nearly equal amounts of DTPA and lysine groups on the polymer chains. The folding is fairly complete by the time the lysine content in the polymeric chelate is 20% of monomer units.
[0044] Efficacy in imaging of tumor lesions arises from the ability of the agent to penetrate through the tumor endothelium, which is promoted dramatically if the polymer is in an extended state capable of reptation, i.e., ability to move around obstacles in snake-like fashion and the ability to penetrate through small diameter pores (P-G de Gennes, Physics Today, June 1983, p. 33). Coiled polymers present a large cross-section and cannot penetrate small pores in the endothelium, so that their effectiveness in marking tumors is much reduced. It is thus essential to produce polymers of extended, uncoiled conformation, to be useful for medical imaging applications.
[0045] Because the kinetics of the anhydride reaction and the coupling reaction are evidently complex, simple manipulations of variables singly do not lead to improvements in conjugation efficiency. Evidently there is a coupling between some of the variables which confounds the interpretation of simple manipulations. The isolation of the key variables was demonstrated in a design of experiments, DOE, procedure in which each of 5 variables was manipulated simultaneously in between high and low levels, with center points chosen between high and low levels, (Box, G. E. P. et al., Statistics for Experimenters, 1978, John Wiley and Sons, New York).
[0046] Variables used in the study included reaction temperature, the TEA to DTPA ratio, the IBCF to DTPA ratio, the concentration of bicarbonate buffer, and the volume of bicarbonate buffer in which the polylysine was dissolved. The ranges for these variables are given in Table 1.
[0047] In general, to produce a purified DTPA substituted polymer in accordance with a preferred embodiment of the invention, a polylysine salt, such as poly-L-lysine hydrobromide, is dissolved in a 0.1M aqueous sodium bicarbonate solution having a pH in the range of between about 8 and about 9.5, which is then cooled to about 0° C. Then DTPA and an acid acceptor are added to a dipolar aprotic solvent, preferably dry, nitrogen purged acetonitrile. This second solution is stirred until the DTPA is dissolved. Under a dry nitrogen purge, this second solution is cooled down to at least a temperature of −35° C. and an alkyl chloroformate, such as isobutylchloroformate, is added to this second solution to form a slurry. The slurry is then added to the cooled polylysine/sodium bicarbonate solution under vigorous mixing, and the resulting mixture is allowed to warm slowly to room temperature and is stirred for 15 to 20 hours. Standard biological separation techniques yield the purified DTPA substituted polymer, which may then be derivatized further with appropriate cationic species such as Fe, Gd, Tc or Mn.
[0048] In single variable testing, it was known that the DTPA anhydride/lysine molar ratio was important, and that ratios in excess of 6 yielded essentially similar results. Therefore, the ratio of DTPA anhidride to lysine residue ratio was set at or above 6 for the entire DOE, and not included as an independent variable. Temperature was also known to be a factor, but appeared non-linear, and was included in the DOE.
[0049] Several of the variables appear to affect the reaction. The primary effect of temperature overwhelms the DOE in its entirety, with high temperature (−15° C.) data points yielding completely unsatisfactory polymer. Relaxivity tests on these materials yield meaningless results. However, when the low temperature (−45° C.) quadrant is analyzed independently, other variables demonstrate increased importance. Merely using sufficient DTPA anhydride, and dropping the temperature of the anhydride reaction is insufficient to yield consistent, highly conjugated polylysine. Moving the remainder of the variables to the highest performing corner achieved consistent conjugation of between 93 and 97%.
TABLE 1 Variation of reaction variables in a DOE configuration. Temp. Bicarb DTPA TEA IBCF (IBCF) [Bicarb] Volume PL Conjug % RI 1.2107 2.25 0.28 −15 1 14 0.113 ˜45 1.2137 2.24 0.44 −45 0.1 6 0.12137 94 7.4 1.214 2.1 0.28 −45 1 14 0.1214 80 9.5 1.2121 2.15 0.36 −30 0.5 10 0.0998 73 8.2 1.2133 2.05 0.28 −45 0.1 6 0.1054 97 8.7 1.2126 2.25 0.44 −45 1 14 0.1008 88 8.8 1.2121 2.05 0.44 −15 0.1 6 0.1001 60 1.2131 2.15 0.36 −30 0.5 10 0.1105 71 9.6 1.2127 2.05 0.44 −45 0.1 14 0.1033 90 7.7 1.2135 2.24 0.44 −16 0.1 14 0.1058 60 1.2156 2.25 0.28 −15 0.1 6 0.0983 65 1.2131 2.05 0.44 −14 1 14 0.1136 <12 1.2125 2.05 0.28 −15 0.1 14 0.1022 <11 1.2118 2.15 0.36 −30 0.5 10 0.1065 76 8.7 1.2116 2.15 0.36 −30 0.5 10 0.0978 75 9.1 1.21 2.05 0.44 −45 1 6 0.1009 94 8.7-8.9 1.2128 2.05 0.28 15 1 6 0.1114 1.2114 2.25 0.28 −43 1 14 0.0999 67 9.5
[0050] Typical results for the method described by Sieving et al. ( Bioconjugate Chem. 1:65-71, 1990) and three repetitions of the modified method, scaled up to 500 mg initial polylsine-HBr are described in Table 2. It is seen that the desired surrogate marker for conformation is best for the modified reaction and that the previous method does not yield extended polymers after labeling with Gd in 4 synthesis runs.
TABLE 2 Degree of conjugation of DTPA and the relaxivity of polymeric products according to Method I and Method II Method Conjugation, % Relaxivity, R1 Method I (Sieving) 82 10 84 10.4 89 9.7 76 9.8 Method II (Improved) 93 8 94 7.4 90 7.7
[0051] The method II protocol is as follows:
[0052] 500 mg of poly-L-lysine hydrobromide are dissolved in 60 mL of 0.1 M aqueous sodium bicarbonate solution having a pH of 9, which is then cooled in an ice bath to 0° C. Then 6.05 g diethylaminetriaminepentaacetic acid, and 10.25 mL of triethylamine are added under nitrogen to 120 mL of dry, nitrogen purged acetonitrile. The solution is stirred at 50-55° C. until the DTPA is dissolved, which typically requires ½ hour or longer. Under a dry nitrogen purge, the DTPA solution is cooled to −45° C., and 2.2 mL of isobutylchloroformate are added dropwise to the solution using a syringe. The solution becomes cloudy, turning to a grayish white slurry. After stirring for 1 hour, the resulting slurry is added dropwise to the polylysine/sodium bicarbonate solution under vigorous mixing at 0° C. The resulting mixture is allowed to warm slowly to room temperature and stirred for 15 to 20 additional hours. Standard biological separation techniques yield the purified, DTPA substituted polymer, which can then be derivatized further with appropriate cationic species.
[0053] From the foregoing, it is apparent that an extended linear polymer of Gd—DTPA-polylysine is an excellent MRI contrast agent for enhancing tumor contrast. In particular, it may delineate tumor angiogenesis parameters at a higher sensitivity than can be done with other MRI contrast agents. Such polymers could be used to deliver therapeautic agents as well, and labeling the polymer with positron emitting elements for use in positron emission tomography (PET) imaging would also be feasible. The key feature of the agent is its ability to penetrate the tumor endothelium and to be retained in the tumor intersitium for an extended period after injection into the blood stream.
[0054] While only certain preferred features of the invention have been illustrated and described, many modifications and changes will occur to those skilled in the art. It is, therefore, to be understood that the appended claims are intended to cover all such modifications and changes as fall within the true spirit of the invention. | Linear extended polymeric paramagnetic chelates for use as MRI contrast agents are synthesized by conjugating DTPA chelator moieties to higher than 90% of the monomer residues of the polyamino acid backbone chain. The resulting polymer can be labeled with Gd, since each chelator moiety holds a Gd ion, and the resulting conformation is of an unfolded, extended linear type, capable of entering small pores and moving around obstacles in the extracellular space of tissues. The efficient production of these extended polymers is critical for the application of such contrast agents to medical imaging. One such agent is a reptating polymer containing technetium-99. | 0 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation of U.S. application Ser. No. 11/761,620, filed on Jun. 12, 2007, which claims priority to Korean Patent Application No. 2007-12274 filed on Feb. 6, 2007, the disclosures of which are each incorporated herein by reference in their entireties.
BACKGROUND
[0002] The present disclosure relates to semiconductor memories. More specifically the present disclosure relates to flash memories and a memory card system including the same.
[0003] Multimedia cards (MMCs) are kinds of communication media and data storage units generally used in low-priced devices intended for normal users. MMCs are usually designed to be operable in various applications, such as smart phones, cameras, personal data assistants (PDAs), digital recorders, MP 3 players, pagers, and so forth. MMCs are nowadays regarded as being characterized by high portability and good performance with low prices.
[0004] FIG. 1 is a schematic block diagram of a general multimedia card.
[0005] Referring to FIG. 1 , the MMC 20 includes an MMC controller chip 22 and a flash memory 24 . The MMC controller chip 22 and the flash memory 24 are each constructed as independent chips. In other words, the MMC 20 is composed of two chips. The flash memory 24 is formed in a NAND type that is well known in this art. The MMC controller chip 22 functions to conduct interfacing operations between a host 10 and the flash memory 24 .
[0006] As the MMC 20 is organized of two chips, the cost is increased for fabricating the MMC 20 . Further, data security would be worse due to exposure of data that is transceived between the MMC controller chip 22 and the flash memory 24 .
[0007] With the object of solving those problems, a way of fabricating a one-chip MMC 40 has been recently proposed, as illustrated in FIG. 2 . In the MMC 40 , an MMC controller 44 and a flash memory 46 are integrated in a single memory chip 42 . Since the one-chip MMC 40 can be structured without pads and signal lines for connecting the MMC controller 44 with the flash memory 46 , it makes the chip area smaller and can be produced at a lower cost. Moreover, without exposure of data transferred between the MMC controller 44 and the flash memory 46 , it enhances the data security.
[0008] Generally, wide-scope applications and diverse users usually require MMCs that are variable in storage capacities. If a number of the flash memories 24 are provided in the MMC 20 shown in FIG. 1 and changes made to a firmware of the MMC controller 22 , a capacity of the MMC 20 may be variable.
[0009] It is not easy, however, for the MMC 40 to vary the storage capacity of the flash memory. To change a storage capacity of the flash memory, it is required to fabricate a memory chip using newly designed circuit patterns and providing plural memory chips to the MMC. In organizing an MMC with pluralities of memory chips, there needs to be considered an interface pattern between a host and the MMC.
SUMMARY OF THE INVENTION
[0010] Exemplary embodiments of the present invention are directed to provide a memory card with a plurality of memory chips and a memory system including the same.
[0011] An exemplary embodiment of the present invention is a memory card being comprised of: a first memory chip responding to all commands input externally; and a second memory chip responding to commands, among the commands input externally, relevant to reading, programming, and erasing operations with data. Card identification information stored in a first memory chip includes capacity information corresponding to a sum of the sizes of the first and second memory chips.
[0012] The second memory chip stores the same card identification information as the first memory chip.
[0013] In an exemplary embodiment, the first memory chip is comprised of: a first flash memory; and a first controller operating to control the first flash memory.
[0014] In an exemplary embodiment, the first flash memory is comprised of: a memory cell array; and a peripheral block configured to control reading, programming, and erasing operations of the memory cell array by the first controller.
[0015] In an exemplary embodiment, the memory cell array of the first flash memory stores the card identification information.
[0016] According to an exemplary embodiment, the first controller is comprised of a register for storing the card identification information read out by a peripheral block at a power-up time.
[0017] In an exemplary embodiment, the first controller of the first memory chip outputs the card identification information externally of the MMC in response to a command input externally.
[0018] According to an exemplary embodiment, the first controller is comprised of: a CPU; a host interface configured to communicate externally in an multimedia card interface mode under control of a CPU; a flash interface configured to control the peripheral block under control of the CPU; and a buffer RAM connected between the host interface and flash interface and configured to temporarily store transmission data.
[0019] In an exemplary embodiment, the second memory chip is comprised of: a second flash memory; and a second controller operating to control the second flash memory.
[0020] According to an exemplary embodiment, the second flash memory is comprised of: a memory cell array; and a peripheral block configured to control reading, programming, and erasing operations of the memory cell array by the second controller.
[0021] In an exemplary embodiment, the memory cell array of the second flash memory stores the card identification information.
[0022] In an exemplary embodiment, the second controller of the second memory chip is comprised of a register for storing the card identification information read out by the peripheral block at a power-up time.
[0023] The second controller is comprised of: a CPU; a host interface configured to communicate externally in an multimedia card interface mode under control by the CPU; a flash interface configured to control a peripheral block under control by the CPU; and a buffer RAM connected between the host interface and a flash interface and configured to temporarily store transmission data.
[0024] An exemplary embodiment of the present invention provides a memory system being comprised of: a host; and a multimedia card configured to communicate with the host. The multimedia card is comprised of: a first memory chip responding to all commands input from the host; and a second memory chip responding to commands, among the commands input from the host, relevant to writing and reading operations with data. Card identification information stored in the first memory chip includes capacity information corresponding to a sum of the sizes of the first and second memory chips.
[0025] In an exemplary embodiment, the second memory chip stores the same card identification information as the first memory chip.
[0026] Each of the first and second memory chips is comprised of: a flash memory; and a controller operating to control the flash memory.
[0027] According to an exemplary embodiment, the flash memory is comprised of: a memory cell array; and a peripheral block configured to control reading, programming, and erasing operations of the memory cell array by the controller.
[0028] In an exemplary embodiment, the memory cell array stores the card identification information.
[0029] In an exemplary embodiment, the controller is comprised of a register for storing the card identification information read out by the peripheral block at a power-up time.
[0030] According to an exemplary embodiment, the host provides the multimedia card with a command for reading the card identification information in a card identification mode, and the first memory chip of the multimedia card outputs the card identification information to the host in response to the read command provided from the host.
[0031] The controller comprises a ROM storing firmware to control the flash memory.
[0032] In an exemplary embodiment, the host provides the multimedia card with an address while accessing the multimedia card. The controller operates to control access to a memory cell array corresponding to the address if the address provided from the host belongs to a first address group. The controller operates to control access to a memory cell array corresponding to the address if the address provided from the host belongs to a second address group.
[0033] In an exemplary embodiment, the first address group includes odd-ordered addresses and the second address group includes even-ordered addresses.
[0034] Exemplary embodiments of the present invention may also provide a method of operating a memory system having a host and a multimedia card including first and second memory chips. The method includes the steps of: connecting the multimedia card to the host; transferring card identification information to the host from the first memory chip of the multimedia card; and executing a reading, programming, or erasing operation of the first or/and second memory chips under control of the host. Card identification information stored in the first memory chip includes capacity information corresponding to a sum of the sizes of the first and second memory chips.
[0035] In an exemplary embodiment, the second memory chip stores the same card identification information as the first memory chip.
[0036] In an exemplary embodiment, each of the first and second memory chips is a flash memory chip.
[0037] According to an exemplary embodiment, the method further includes the step of converting an address, which is provided from the host, into a first address for accessing the first memory chip if the address provided from the host belongs to a first address group.
[0038] According to an exemplary embodiment, the method further includes the step of converting an address, which is provided from the host, into a first address for accessing the second memory chip if the address provided from the host belongs to a second address group.
[0039] In an exemplary embodiment, the first address group includes odd-ordered addresses and the second address group includes even-ordered addresses.
[0040] A further understanding of the nature and advantages of the exemplary embodiments of the present invention herein may be realized by reference to the remaining portions of the specification and the attached drawings.
BRIEF DESCRIPTION OF THE FIGURES
[0041] Exemplary embodiments of the present invention will be understood in more detail from the following descriptions taken in conjunction with the accompanying figures. In the figures:
[0042] FIG. 1 is a schematic block diagram of a general multimedia card;
[0043] FIG. 2 is a schematic block diagram of a one-chip multimedia card;
[0044] FIG. 3 is a block diagram of a memory system including a multimedia card in accordance with an exemplary embodiment of the present invention;
[0045] FIG. 4 is a block diagram concretely illustrating a functional structure of a first memory chip of the system shown in FIG. 3 ;
[0046] FIG. 5 is a flow chart showing an operation of a memory card system according to an exemplary embodiment of the present invention;
[0047] FIG. 6 is a flow chart showing an operation of a multimedia card controller of a second memory chip in the memory card system according to an exemplary embodiment of the present invention;
[0048] FIG. 7 is a schematic diagram illustrating a feature of designating flash memories in two memory chips by means of an address input from a host;
[0049] FIG. 8 is a schematic diagram illustrating a feature of designating flash memories in two memory chips in an interleaving mode by means of an address input from a host; and
[0050] FIG. 9 is a block diagram of a memory system according to an exemplary embodiment of the present invention.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0051] Exemplary embodiments of the present invention will be described below in more detail with reference to the accompanying drawings. The present invention may, however, be embodied in different forms and should not be constructed as limited to the exemplary embodiments set forth herein. Rather, these exemplary embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the present invention to those of ordinary skill in the art. Like reference numerals refer to like elements throughout the accompanying figures.
[0052] FIG. 3 is a block diagram of a memory system including a multimedia card in accordance with an exemplary embodiment of the present invention.
[0053] Referring to FIG. 3 , the memory system 1000 is comprised of an MMC host 100 and an MMC 200 . The MMC 200 according to an exemplary embodiment of the present invention is designed to communicate with the MMC host 100 in an MMC interface mode. This means that the MMC 200 is used as a multimedia card. The MMC 200 includes first and second memory chips 220 and 240 . The first memory chip 220 includes an MMC controller 222 and a flash memory 224 , formed as a single chip. The second memory chip 240 also includes an MMC controller 242 and a flash memory 244 , formed as a single chip. A memory cell array (not shown) contains firmware for managing the flash memory. The structure and operation of the first memory chip 220 will be representatively described hereinafter, since there is a similarity between the first and second memory chips 220 and 240 .
[0054] The MMC 200 shown in FIG. 3 is organized including the two memory chips 220 and 240 . Those memory chips 220 and 240 store the same chip identification
[0055] (ID). Capacity information provided to the MMC host 100 from the first memory chip 220 is a sum of storage capacities of the flash memories 224 and 244 . The flash memories 224 and 244 are accessed by addresses that are different from each other. The MMC host 100 accesses the MMC 200 in the same mode of making a connection with an MMC having a single flash memory that corresponds to the sum of the capacities of the flash memories 224 and 244 .
[0056] FIG. 4 is a block diagram illustrating a functional structure of the first memory chip 220 shown in FIG. 3 .
[0057] Referring to FIG. 4 , the MMC controller 222 of the first memory chip 220 is comprised of a central processing unit (CPU) 311 , a ROM 312 , a host interface 313 , a buffer RAM 314 , a flash interface block 315 , and registers 316 connected to the CPU 311 . The ROM 312 stores firmware for managing the flash memory 224 . The CPU 311 operates in response to a command transferred through the host interface 313 over the system bus and manages the flash memory 224 by means of the firmware stored in the ROM 312 . The ROM 312 stores a card firmware code.
[0058] The host interface 313 provides an interface operation with the host 100 of FIG. 3 . For instance, the host interface 313 converts serial data/addresses, which are transferred from the host 100 , into parallel data/addresses. The flash interface block 315 provides an interface operation with the flash memory 224 . The flash interface block 315 is controlled by the CPU 311 and configured to generate control signals and addresses necessary for reading, programming, and erasing operations. The flash interface block 315 is designed, for example, to control timings in reading, programming, and erasing operations of the flash memory 224 .
[0059] The buffer RAM 314 is used as a work RAM of the CPU 311 . The buffer RAM 314 is also used for provisionally storing data transferred between the host 100 of FIG. 3 and the flash memory 224 . The host 100 and the MMC 200 are configured to operably communicate by way of various interface devices (not shown), such as peripheral component interconnect (PCI), universal serial bus (USB), and so on.
[0060] As shown in FIG. 4 , the flash memory 224 includes a memory cell array 330 and a peripheral block 340 . A specific field of the memory cell array 330 stores a card ID and operation parameters, for example, a flash memory size, the maximum data access time, a data transmission rate, and so on. The card ID and operation parameters stored in the specific field of the memory cell array 330 are stored into the registers 316 of the MMC controller 222 at a power-up time under control of the CPU 311 .
[0061] The peripheral block 340 conducts reading, programming, and erasing operations by the MMC controller 222 . The peripheral block 340 is arranged to include row and column decoders 341 and 342 , a command decoder 343 , a control logic unit (controller logic) 344 , a page buffer circuit 345 , a column gate circuit (Y-gating) 346 , and input/output buffer and latch circuit (I/O buffer and latches) 347 . The elements of the peripheral block 340 are well known by those of ordinary skill in this art, so will not be described further.
[0062] The chip ID and operation parameters stored in the registers 316 of the first memory chip 220 are identical to those stored in registers (not shown) of the second memory chip 240 of FIG. 3 . Therefore, a card identification mode, in which at a power-up time the MMC host 100 requests the chip ID and operation parameters of the MMC 200 , can succeed by providing card identification information to the MMC host 100 from any one of the first and second memory chips 220 and 240 . In this exemplary embodiment of the present invention, setting the first memory chip 220 as a primary chip, the first memory chip 220 responds to a request for card identification information by the host 100 shown in FIG. 3 .
[0063] The host 100 outputs addresses to the MMC 200 in a packet mode with reference to an MMC protocol. The MMC 200 executes a reading, programming, or erasing operation with addresses provided from the host.
[0064] A group of addresses provided from the host 100 is mapped to the flash memory 224 of the first memory chip 220 , while the other group is mapped to the flash memory 244 of the second memory chip 240 . This address mapping scheme is accomplished by MMC controllers 222 and 242 .
[0065] FIG. 5 is a flow chart showing an operation of the MMC controller 222 in the first memory chip 220 of the memory card system according to an exemplary embodiment of the present invention. Hereinafter will be detailed the operation of the MMC controller 222 in the first memory chip 220 according to an exemplary embodiment of the present invention.
[0066] As well known, if the MMC 200 links to the host 100 , power is supplied into the MMC 200 from the host. Once power is supplied to the MMC 200 , the MMC 200 is put into a well-known card identification mode. While power is being supplied to the first memory chip 220 of the MMC 200 , the card ID and operation parameters stored in the memory cell array 330 are stored into the registers 316 under control of the CPU 311 (step 510 ). The card ID and operation parameters stored in the registers 316 are transferred to the host 100 in accordance with a known process in the card identification mode. Upon issuing a first command CMD1 520 , the ready state 530 is set and, upon issuing a second command CMD2 540 , an identification state 550 is set. Then, upon issuing a third command CMD3 560 , a decision 570 is made whether all of the card ID is in. Steps 520 ˜ 570 of FIG. 5 are arranged to conduct the card identification mode. As the card identification mode is well known in this art, it will not be described further.
[0067] If the card identification mode is terminated, the first memory chip 220 of the MMC 200 is put into a stand-by state for a data transfer mode (step 580 ). During the data transfer mode, the flash memory 224 is managed by the MMC controller 222 .
[0068] FIG. 6 is a flow chart showing an operation of the MMC controller 242 in the second memory chip 240 of the memory card system according to an exemplary embodiment of the present invention.
[0069] Referring to FIGS. 4 and 6 , if power is supplied to the MMC 200 , the second memory chip 240 of the MMC 200 is put into a card identification mode together with the first memory chip 220 . While power is being supplied to the second memory chip 240 , the card ID and operation parameters stored in the memory cell array 330 of the flash memory 244 are stored into registers 316 under control of the CPU 311 of the MMC controller 242 (step 610 ). The card ID and operation parameters about the second memory chip 240 are not transferred to the host 100 , because those are identical to the card ID and operation parameters of the first memory chip 220 that have already been transferred.
[0070] If the card identification mode is terminated, the second memory chip 240 of the MMC 200 is put into a stand-by state for a data transfer mode (step 620 ). During the data transfer mode, the flash memory 244 is managed by the MMC controller 242 .
[0071] The host 100 outputs addresses to the MMC 200 for reading, programming, and erasing operations. The controller 222 of the MMC 200 operates to control a reading, programming, or erasing operation correspondent to a command input from the host 100 when an address supplied from the host 100 belongs to a group of addresses for designating the flash memory 224 . The controller 242 of the MMC 200 operates to control a reading, programming, or erasing operation corresponding to a command input from the host 100 when an address supplied from the host 100 belongs to the other group of addresses for designating the flash memory 244 .
[0072] FIG. 7 is a schematic diagram illustrating a feature of designating flash memories in two memory chips by means of an address input from a host.
[0073] Referring to FIG. 7 , a group of addresses A 1 ˜A k among addresses A 1 ˜A n provided from a host 710 is used for designating a flash memory 724 of a first memory chip 720 , while the other group of address A k+1 ˜A n among the addresses A 1 ˜A n provided from the host 710 is used for designating a flash memory 734 of a second memory chip 730 .
[0074] An MMC controller 722 of the first memory chip 720 operates to control a reading, programming, or erasing operation corresponding to a command input from the host 710 when an address supplied from the host 710 belongs to the address group of A 1 ˜A k . An MMC controller 732 of the second memory chip 730 operates to control a reading, programming, or erasing operation corresponding to a command input from the host 710 when an address supplied from the host 710 belongs to the other address group of A k+1 ˜A n .
[0075] FIG. 8 is a schematic diagram illustrating a feature of designating flash memories in two memory chips in an interleaving mode by means of an address input from a host.
[0076] Referring to FIG. 8 , odd-ordered addresses A 1 , A 3 , . . . , and A n−1 among addresses A 1 ˜A n provided from a host 810 are used for designating a flash memory 824 of a first memory chip 820 , while the even-ordered address A 2 , A 4 , . . . , and A n among the addresses A 1 ˜A n provided from the host 810 are used for designating a flash memory 834 of a second memory chip 830 .
[0077] An MMC controller 822 of the first memory chip 820 operates to control a reading, programming, or erasing operation corresponding to a command input from the host 810 when an address supplied from the host 810 belongs to the odd-ordered addresses A 1 , A 3 , . . . , and A n−1 . An MMC controller 832 of the second memory chip 830 operates to control a reading, programming, or erasing operation corresponding to a command input from the host 810 when an address supplied from the host 810 belongs to the even-ordered addresses A 2 , A 4 ,. . . , and A n .
[0078] As such, when the host 810 accesses the flash memories 824 and 834 in the interleaving mode, there may be an overlap between timings of accessing the flash memories 824 and 834 by the host 810 and, hence, this provides an improvement of a data transmission rate between the host 810 and the MMC 800 .
[0079] In an exemplary embodiment, the flash memories of two memory chips may be divided into the units of a page or a block. As an example, the first memory chip is accessed if an address input from the host corresponds to an address for designating an odd-ordered page, while the second memory chip is accessed if an address input from the host corresponds to an address for designating an even-ordered page. Otherwise, the first memory chip is accessed if an address input from the host corresponds to an address for designating a group of pages in order of 1, 2, 5, 6, 9, . . . , while the second memory chip is accessed if an address input from the host corresponds to an address for designating the other group of pages in order of 3, 4, 7, 8, 11, 12, . . . . As such, this interleaving mode wherein the host accesses the flash memories may generate an overlap between timings of accessing the flash memories by the host, so it improves data transmission rate between the host and the MMC.
[0080] FIG. 9 is a block diagram of a memory system according to an exemplary embodiment of the present invention.
[0081] Referring to FIG. 9 , the memory system is organized including an MMC host 910 , and MMCs 930 and 940 coupled to the host 910 through an MMC bus 920 . The MMCs 930 and 940 coupled to the MMC bus 920 store the same card ID. A primary card, among the MMCs 930 and 940 , provides the host 910 with card identification information that includes data corresponding to a sum of the .storage capacities of the MMCs 930 and 940 . Therefore, the host 910 generates signals for accessing the MMCs 930 and 940 as same as the case that the MMC bus is coupled to an MMC including a single memory corresponding to a sum of the storage capacities of the MMCs 930 and 940 .
[0082] Each of the MMCs 930 and 940 includes an MMC controller (not shown) and a flash memory (not shown). The controller of the MMC 930 operates to control a reading, programming, or erasing operation corresponding to a command input from the host 910 when an address supplied from the host 910 belongs to a group of addresses. The controller of the MMC 940 operates to control a reading, programming, or erasing operation corresponding to a command input from the host 910 when an address supplied from the host 910 belongs to the other group of addresses.
[0083] According to such an MMC system, it is possible to obtain, by coupling two or more MMCs to the MMC bus 920 , the same effect as the case of increasing the capacity of a single MMC.
[0084] Whereas the exemplary embodiments by the present invention have been described in conjunction with an MMC, it is permissible to apply the present invention to various types of card systems connectable and communicable with a host and including a memory chip, for example, Secure Digital (SD) cards, USB memories, Compact Flash (CF) memories, and so on.
[0085] According to exemplary embodiments of the present invention as described above, the memory card is able to include pluralities of memory chips. Thus, it is easy to design a capacity of the memory card in various ways. Moreover, by using the same card ID of the plural MMCs coupled to the MMC bus, it is possible to obtain the same effect as in the case of increasing a capacity of a single MMC.
[0086] The above-disclosed subject matter is to be considered illustrative and not restrictive, and the appended claims are intended to cover all such modifications, enhancements, and other exemplary embodiments, which fall within the true spirit and scope of the present invention. Thus, to the maximum extent allowed by law, the scope of the present invention is to be determined by the broadest permissible interpretation of the following claims and their equivalents, and shall not be restricted or limited by the foregoing detailed description. | A memory card includes: a first memory chip responding to all commands input externally; and a second memory chip responding to commands, among the commands input externally, relevant to reading, programming, and erasing operations with data. Card identification information stored in the first memory chip includes capacity information corresponding to a sum of sizes of the first and second memory chips. The plurality of memory chips of the memory card are useful in designing the memory card with storage capacity in various forms. | 6 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims priority to U.S. Provisional Application No. 62/239,440 filed on Oct. 9, 2015, which is incorporated herein in its entirety by reference.
FIELD
[0002] The present disclosure relates to animal waste collection apparatus.
BACKGROUND
[0003] Many cities and municipalities have enacted laws requiring domestic animal owners to restrain their pet animals particularly dogs, by having them attached to a leash, and, as well, to retrieve their fecal deposits. The pet owner is required to “cleanup” after their dogs so as to prevent others from stepping in or on the waste, and to inhibit the health risk associated with its presence.
[0004] The conventional technology provides devices for aiding pet owners with the odious and generally unpleasant task involved in collecting dog feces left by their pets. Not only are the tasks are difficult and odious the apparatus available for such use often is awkward to carry and to use. The prior art has suggested devices are difficult to carry and may not be easily employed without risking getting, the fecal material on his or her hands or apparel.
[0005] U.S. Pat. No. 7,931,170 B2 discloses a pet waste bag dispenser including a pouch body, a pouch cover, means for detachably attaching the pouch cover on the front wall of pouch body, and a bag dispenser for user's convenience.
[0006] U.S. Pat. No. 8,505,770 B2 discloses an animal waste bag dispenser Wherein roll of waste bags with leading waste bag protruding from the center is inserted into a holder with an aperture on one end, and the holder is inserted into a plush animal with a second aperture aligned with first aperture so that the waste bags may be dispensed.
[0007] Patent No US 20100237640 A1 discloses a pet waste collection and temporary storage system, comprising a pet waste receptacle container and a leash clip.
[0008] U.S. Pat. No. 6,314,917 B1 discloses a retractable leash pack which is a compartmentalized pack made of typical back pack materials such as Nylon, webbing, mesh and VELCRO®—that fits securely to a retractable dog leash.
[0009] Patent No US 20090315350 A1 discloses a carrier that can be used to collect and transport items. The carrier may be used in connection with the pick-up and disposal of waste item& including but not limited to, animal waste.
[0010] it is therefore desirable to provide a convenient dispenser for plastic bags for collecting waste to be carried during walks. Additionally, it is desirable that such a device accommodate storage of waste bags when filled.
SUMMARY
[0011] The present disclosure provides an improved apparatus for storing pet's excreta in dispensable bag to be carried easily by the pet owner or attached to pet leash or by pet. The general purpose of the present disclosure, which will be described subsequently in greater detail, is to provide a new pet waste collection apparatus for making waste to be more easily collected and carried. Further, the present disclosure provides a waste collection apparatus that can be comfortably and securely worn by a user or attached to a pet leash or worn by a pet, while taking the pets for walk.
[0012] In an example embodiment, the present disclosure provides an apparatus that can store accessories commonly carried by a user while taking his pet for walk. Accordingly, the apparatus includes pouch with separate compartments for roll of waste bags and storing the filled waste bag.
[0013] In an example embodiment the present disclosure provides as means for readily is accessing the bags stored in the apparatus.
[0014] It is yet another example embodiment, the present disclosure provides a means for tethering the pet to the apparatus to allow the user to walk free when needed or desired.
[0015] In yet another example embodiment, the present disclosure provides a pet waste bag dispenser, so as to dispense rolls of waste bags.
[0016] Features and advantages of the present disclosure will be readily apparent to those of ordinary skill in the art upon reading of the following detailed description and embodiments of the present disclosure when taken in conjunction with the accompanying drawings. The inventive aspects of the disclosure are capable of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of descriptions and should not be regarded as limiting.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] To further clarify various aspects of example embodiments of the present disclosure, a more particular description will be rendered by reference to specific embodiments thereof which are illustrated in the drawing. It is appreciated that the drawing depicts only illustrated embodiments of the disclosure and are therefore not to be considered limiting of its scope. The disclosure will be described and explained with additional specificity and detail through the use of the accompanying drawing in which:
[0018] FIG. 1 shows a perspective view of a pet waste collection apparatus according to an example embodiment;
[0019] FIG. 2 shows another perspective view of the pet waste collection apparatus according to an example embodiment;
[0020] FIG. 3 shows another prospective view of the pet waste collection apparatus in an open position according to an example embodiment;
[0021] FIG. 4 shows a perspective view of the pet waste collection apparatus in a closed position according an example embodiment.
DETAILED DESCRIPTION
[0022] The embodiments of the present disclosure described below are not intended to be exhaustive or to limit the disclosure to the precise forms disclosed in the following detailed description. Rather, the embodiments are chosen and described so that others skilled in the art may appreciate and understand the principles and practices of the present disclosure.
[0023] In the following description, reference is made to the accompanying drawings which form a part hereof, and in which is shown by way of illustration specific embodiments in which the inventive concept may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the inventive concept, and it is to be understood that the embodiments may be combined, or that other embodiments may be utilized and that structural and logical changes may be made without departing from the spirit and scope of the present inventive concept. The following description is, therefore, not to be taken in a limiting, sense.
[0024] Example embodiments of the inventive concepts may be embodied in many different forms and should not be construed as being 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 concept of example embodiments to those of ordinary skill in the art. In the drawings, some dimensions are exaggerated for clarity.
[0025] It will be understood that when an element is referred to as being “connected” or “coupled” to another element, it can be directly connected or coupled to the other element or intervening elements may be present.
[0026] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of example embodiments of the inventive concepts. As used herein, the singular forms “a,” “an” and “the” are intended to include, the plural Rums as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises”, “comprising”, “includes” and/or “including,” if used herein, specify the presence of stated features, integers, steps, operations, elements and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components and/or groups thereof.
[0027] Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which example embodiments of the inventive concepts belong. It will be further understood that terms, such as those defined in commonly-used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.
[0028] In some embodiments, the present disclosure provides improved pet waste collection apparatus to conveniently carry and store pet waste containing bags. The purpose of the disclosure is to provide user friendly, easy to use carry pet waste collection apparatus.
[0029] This section summarizes some aspects of the present disclosure and briefly introduces some embodiments. Simplifications or omissions in this section as well as in the abstract or the title of this description may be made to avoid obscuring the purpose of this section, the abstract and the title. Such simplifications or omissions are not intended to limit the scope of the present disclosure nor imply any limitations.
[0030] FIGS. 1-2 show a pet waste collection apparatus 10 which includes a receptacle 10 ( a ) containing a simple collection pouch 15 that cart be used to carry pet waste in bags. The apparatus 10 includes a section 11 , accessible from the outside to hold bags from a roll or singly inserted. The apparatus 10 includes aerating holes 12 ( a ), 12 ( b ) at the bottom of the receptacle to allow thorough aeration and keep odors away from the collector. The receptacle 10 ( a ) is provided with attachment means or posterior rivets 13 ( a ), 13 ( b ) to allow for several transport attachments. Further, the receptacle 10 ( a ) is provided with a light opaque stiff plastic with flap closure with hook or fastening means 14 ( a ), 14 ( b ) and pile seal to allow it to be resistant to the elements, and is simple to clean. The flap includes top Velcro attachment to attach the flap with the Velcro 14 as shown in FIGS. 1-2 .
[0031] In an example embodiment, the collection apparatus 10 may be a plastic bag enclosure.
[0032] The disclosed apparatus 10 , as shown in FIGS. 1-2 provides an improved pet waste collection apparatus, by providing a bag like enclosure 10 with compartmentalized setup inside, a separate space 11 for carrying waste bag roll or individual waste bag. The rest of space is used as a collection pouch 15 for carrying the used waste bag conveniently. The posterior rivets 13 ( a ), 13 ( b ) are provided for attaching several transport attachments with the bag 10 for easily carrying the bag 10 by a user, or for attaching to a pet leash or pet.
[0033] The bag 10 includes an enclosure that constitutes various rivet positions within the enclosure, including a small opening 16 for easily accessing the space containing waste bag roll to roll out individual waste bag for collecting and carrying the pet's waste, as shown in open and closed view of the pet waste collection apparatus in FIGS. 3-4 . The posterior rivets 13 ( a ), 13 ( b ) can be used for attaching various types of attachment means like a jacket pull type attachment to leash 17 , or for clips 18 . The belt clips 19 can also attach directly to pants or belt or backpack pockets as shown in FIG. 3 .
[0034] In an example embodiment, the disclosed bag 10 is made in different sizes and specifications. In an example embodiment, the bag is 16 cm long, 10 cm high and 6 cm wide with a storage space 22 taking up to 5 cm wide internal portion from one side.
[0035] In another example embodiment, the bag ma be 15-19 cm long, 9-12 cm high and 5-8 cm wide bag with a storage space 22 taking up 5 cm wide internal portion from one side.
[0036] In some embodiments, the stiff opaque plastic is folded at corners and glued on inside to alleviate .sharp comers and is provided with posterior open rivets to allow for interchangeable carrying options, interior open holes to allow for aeration and drainage if needed. It can further include a “zipper pull” type rope to thread through posterior rivets and plastic clips to allow for attachment to packs and leashes etc.
[0037] Accordingly, the invention provides a sanitary animal waste collection pouch for the collection and temporary storage of pet waste, said pouch having front, rear and opposite sides defining an open-topped chamber for receiving pet-waste containing tied is plastic litter bags and having a flap cover carrying an exterior opening pocket and an interior opening pocket. The invention provides sanitary pet waste collection pouch for the collection and temporary storage of animal waste, said bag including an interior open-topped space for holding tied and sealed litter bags loaded with pet-wastes.
[0038] According to another embodiment, the pet waste bag dispenser is designed for the roll of rectangular shaped pet waste bags in such a manner that the pet waste bags can easily be dispensed continuously.
[0039] In another embodiment, the flap is provided for covering the top opening 20 of the bag storage space 15 , so as to protect the pet waste bags disposed within the bag storage space 15 from the top opening 20 and to prevent the pet waste bags from falling off the bag storage space 15 or from damages. The flap has a front cover edge 21 extended from the rear side of the bag 10 for detachably attaching the front cover edge 21 of the bag 10 on the front side of the bag 10 via attachment means such as Velcro.
[0040] In order to ensure that the top opening 20 is to remain closed, the pet waste bag dispenser comprises the attachment means for detachably attaching the front cover edge 21 of the bag 10 on the front side of the bag 10 , wherein the flap is front-wardly folded to cover the to opening 20 of the bag 10 so as to enclose the bag storage space 15 and retaining the pet waste in the bags therein. The apparatus 10 is also provided with an additional LCD clock/alarm on the top. The bag dispenser 22 is adapted for allowing the pet waste bags to be dispensed out of the bag storage space 11 when the bag 10 is enclosed such that the pet waste bags can be pulled out of the bag storage space 11 without having to use both hands to hold on to the pet waste bag dispenser or to have to open up the bag 10 to reach the pet waste bags, allowing a user to effortlessly utilize the pet waste bags, when he/she might not have both hands free as shown in FIG. 3 .
[0041] Although specific embodiments have been illustrated and described herein, it will be appreciated by those of ordinary skill in the art that any arrangement, which is calculated to achieve the same purpose, may be substituted for the specific embodiment shown. This application is intended to cover an adaptations or variations of the present invention.
[0042] Although the invention has been explained in relation to its preferred embodiment, it is to be understood that many other possible modifications and variations can be made without departing from the spirit and scope of the invention. | A pet waste collection bag encloses an open-topped chamber with compartmentalized spaces for aiming waste bag dispenser and retaining filled pet waste bags. The apparatus is provided with opening for maintain aeration and rolling o it the waste hag from a small side oval opening. The bag is provided with an attachment means to connect different types of attachments to attach the apparatus to a user clothes or accessories or to a pet leash or directly with the pet. | 4 |
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