description stringlengths 2.98k 3.35M | abstract stringlengths 94 10.6k | cpc int64 0 8 |
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BRIEF SUMMARY OF THE INVENTION
This invention relates to an apparatus utilizing a bath of boiling solvent for cleaning workpieces or distilling solvent. More specifically, the present invention concerns the energy efficient removal of soluble particulate matter from soiled workpieces to be cleaned by first immersing the workpieces into the boiling solvent and then exposing them to vapors released by the boiling solvent. During the cleaning operation, the boiling solvent is continually vaporized and condensed so as to be recycled.
Prior art vapor degreasing devices disclose attempts to utilize energy efficiently while cleaning workpieces, see for example, U.S. Pat. No. 4,003,798 issued to James W. McCord, dated Jan. 18, 1977 entitled "Vapor Generating and Recovering Apparatus." These devices, however, have not proven entirely satisfactory. Prior art devices generally rely upon a refrigeration system utilizing a primary heat transfer fluid or refrigerant, such as dichlorodifluoromethane (Freon), to directly conduct heat energy to the solvent bath, thereby causing the solvent to boil and vaporize. Moreover, prior art devices utilize the refrigerant in an evaporator coil which contacts the solvent vapor, causing the vapor to condense or cool to a liquid which is recycled back into the solvent bath. The use of a refrigerant as a primary heat transfer fluid in both the heating and cooling sections of the apparatus necessitates coils and conduits containing the low boiling point refrigerant at a high pressure to be disposed within the apparatus. This arrangement presents a safety hazard if the coils or conduits rupture or are inadvertently punctured. Such a safety hazard is particularly evident while the pressurized refrigerant flows through the portion of the apparatus in which the boiling solvent is disposed, namely, the boiling sump of a vapor degreaser.
Further, prior art devices have proved to be less energy efficient during startup and also under heavy load conditions. Such devices, for example, employ a continually operational complementary (auxiliary) heat exchange means or auxiliary condenser for dissipating or emitting excess heat energy from the refrigeration system to the ambient atmosphere in an attempt to maintain a balanced and energy efficient operation of the device, see the McCord patent, supra. Thus, some heat energy is always dissipated from the system by the auxiliary condenser. This continuous heat dissipation proves energy inefficient when a part or all of the dissipated heat energy must be provided from external energy sources in order to maintain the thermodynamically balanced operation of the device.
In the present invention, a conventional refrigeration system including an evaporator and a condenser circulates a refrigerant such as Freon. Associated with both the condenser and evaporator of the conventional refrigeration system is a respective loop system for coupling the heat energy from the condenser to the solvent in the boiling sump of the vapor degreaser and another loop system for coupling the cooling from the evaporator to the solvent vapors in the vapor degreaser. The liquid circulation in these two loops is maintained at a low pressure which is safe in the event of rupture or accidental puncture of the coils and conduits disposed in the tank. The present apparatus, therefore, utilizes a binary system comprising three self-contained loops. A refrigeration system loop conducts a refrigerant and two primary liquid loops conduct a primary heat transfer liquid, preferably water, to the coils and conduits within the tank. The liquid in both of the primary liquid loops may be the same or different. Preferably, both primary loops circulate the same liquid, usually water, because of the high boiling point of water in relation to most commonly used solvents. That is, the water can be heated to a sufficiently high temperature by the condenser to cause the solvent in the sump to boil without the circulating water itself being in a boiling state.
The amount of heat energy required to boil the solvent varies with the work load. Less heat is required to maintain the boiling status of a quiescent reservoir of solvent than is required to maintain the solvent boiling when ambient temperature workpieces are continuously placed into and removed from the reservoir. In order to provide the additional heat when required but also to operate at an optimal energy efficiency, an auxiliary evaporator is used in the refrigeration system. Further, the presence of excess heat energy produced, for example, by the continuous heat of compression of the compressor in the refrigeration system with varying work loads, causes a thermodynamic imbalance in the system. In order to compensate for this energy imbalanced condition, the refrigeration system of the present invention includes an auxiliary condenser for automatically dissipating excess heat energy. The auxiliary condenser is switched completely out of operation when there is no need to dissipate any excess heat energy.
With suitable sensors as hereinafter described, the auxiliary evaporator and the auxiliary condenser may be switched in or out of the refrigeration system for the purpose of extracting heat from the ambient atmosphere or dissipating heat into the ambient atmosphere as is required to maintain the necessary thermodynamic equilibrium for the desired energy efficient operation of the degreasing apparatus with varying work loads.
The provision in the present invention of means to completely disengage the auxiliary condenser from operation enhances energy efficient operation of the degreaser when contrasted with the prior art. Also, heat energy stored from the ambient atmosphere in the primary heat transfer liquid disposed within the primary liquid loops increases the efficiency of the present apparatus by providing a readily available source of thermal energy within the apparatus itself.
A principal object of the present invention, therefore, is the provision of an energy efficient vapor degreasing apparatus.
A further object of this invention is the provision of a degreasing apparatus which simultaneously increases operator safety while operating in an energy efficient manner.
Further and still other objects of the present invention will be more readily apparent from the following description when taken in conjunction with the accompanying drawing.
BRIEF DESCRIPTION OF THE DRAWING
The sole FIGURE is a schematic diagram of a preferred embodiment of the vapor degreasing apparatus comprising the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the sole FIGURE, there is shown a degreasing apparatus comprising a metal tank or housing 11 containing a liquid chamber or boiling sump 14 in which a reservoir or bath of solvent is boiled. As the solvent boils, vapors rise above the level of the liquid solvent. The vapors condense upon contact with the cooling coils 12a disposed around the inside perimeter of the tank 11. A second sump 16 collects the condensed solvent from a lip 13 disposed under the coils 12a. A weir 15 of preselected height disposed between sumps 14 and 16 defines the liquid level of condensed solvent collected within the sump 16. The use of low boiling point solvents in the fluorocarbon or hydrocarbon family, such as dichloromethane, is preferred.
A first closed loop 10 for conducting a primary heat transfer liquid, specifically water or a water based liquid, through heating coils 14a, which are suitably disposed in the sump 14 for causing boiling of the solvent therein, comprises a pump 19 which discharges water which has been heated to a sufficient temperature to cause the solvent in sump 14 to boil, heating coils 14a, the condensing space 25 of a condenser 24 and a liquid expansion storage tank or reservoir 22 in addition to piping connecting the elements together. The primary heat transfer liquid must have good thermal properties and have a boiling point higher than the temperature necessary to cause the solvent in sump 14 to boil.
A second closed loop 20 for conducting a second primary heat transfer liquid, specifically water or a water based liquid, through the cooling coils 12a comprises a pump 62 which discharges water which has been lowered to a temperature sufficient to condense the solvent vapors rising in the tank 11, cooling coils 12a, the evaporator space 57 of an evaporator 56 and liquid reservoir 60 in addition to piping connecting the elements together. The position of the coils 12a defines the vapor and freeboard zones within the tank 11. A temperature sensor 58 is disposed within liquid reservoir 60 and is preset to generate a signal responsive to a predetermined below-ambient temperature of the water within the reservoir 60.
A third closed refrigeration loop 30 for conducting a refrigerant, such as Freon, comprises a compressor 26 of the type commonly used in refrigerating systems, condensing coils 24a of the condenser 24, liquid refrigerant receiver 32, dryer 34, moisture indicator (sight glass) 36, temperature controlled solenoid valve 46 which is coupled to the sensor 58 by means of conductor 47, thermal expansion valve 50, the coils 56a of the evaporator 56 and return piping (conduit) 27 to the compressor 26 in addition to piping connecting the elements together. The refrigerant is compressed to a preselected pressure by the compressor 26. The pressurized refrigerant then passes through the condenser 24 wherein the refrigerant emits or dissipates its heat energy to the water pumped through the condensing space 25 of the condenser 24. Condensed refrigerant then flows through receiver 32, dryer 34, sight glass 36, normally open valve 46, thermal expansion valve 50, evaporating coils 56a, and then through return piping 27 to the compressor 26. Thermal expansion valve 50 lowers the pressure of the refrigerant to a preselected level so as to allow the refrigerant to absorb the heat energy dissipated by the water pumped through the evaporator space 57. The refrigerant conducted through loop 30, therefore, absorbs heat energy within the evaporator 56 and the compressor 26 and emits or dissipates heat energy within the condenser 24.
An auxiliary condenser or bypass branch 31 is coupled with its input end to a point between the intake piping 24c of condenser 24 and the discharge piping 26b of the compressor 26. The output of this branch is coupled to a point between the exit piping 24b of the condenser 24 and the input of the receiver 32. The auxiliary condenser or bypass branch 31, therefore, is coupled to loop 30 and is in parallel with the condensing coils 24a. The branch 31 comprises the series connection of auxiliary condensing coils 40a and a pressure regulating valve 38. Coils 40a are thermally coupled to the ambient atmosphere. When the pressure sensed by regulating valve 38 exceeds a preset value, the valve 38 opens and allows an amount of refrigerant to flow through the branch 31 to the receiver 32 instead of flowing through the condenser 24. The valve 38 opens only when necessary to dissipate excess heat energy from the refrigerant to the ambient atmosphere in order to maintain the thermodynamic balance of the system in an optimally energy efficient manner. A fan 42 is disposed near auxiliary condensing coils 40a and is connected to a motor 43 which rotates the fan at a constant speed. The constant speed of rotation of fan 42 aids the dissipation of heat energy by the refrigerant within coils 40a to the ambient atmosphere.
An auxiliary evaporator or bypass branch 33 is coupled with its input end between the exit piping 36b from sight glass 36 and the entrance piping 46c to the solenoid valve 46. The output end of branch 33 is coupled to the compressor return piping 27. Auxiliary branch 33, therefore, is coupled to loop 30 and is in parallel with the valves 46 and 50 and evaporating coils 56a. Branch 33 comprises in series a normally closed solenoid controlled valve 48 which is coupled by means of conductor 47 to the temperature sensor 58 and switched open and closed in response to a signal therefrom, thermal expansion valve 52 which lowers the pressure of the refrigerant to a preset level and auxiliary evaporating coils 54a which are thermally coupled to the ambient atmosphere. Refrigerant will flow through the auxiliary evaporator branch 33, i.e. through valves 48 and 52 and then coils 54a, only if necessary to maintain the refrigeration system thermodynamic balance in an optimally energy efficient manner with increased work loads.
When the temperature sensor 58 detects a temperature at or below a predetermined value, valve 48 in bypass 33 is switched open and valve 46 in refrigeration loop 30 is switched closed. Thus, the refrigerant in piping section 36b is conducted through the auxiliary evaporating coils 54a into the compressor 26 instead of through the evaporating coils 56a. In this manner, heat is absorbed by the refrigerant from the ambient atmosphere through coils 54a instead of from the water within loop 20 through coils 56a. Auxiliary coils 54a are disposed near the constant speed fan 42 which aids in the exchange of heat energy from the ambient atmosphere to the refrigerant flowing through the evaporating coils 54a.
DESCRIPTION OF THE OPERATION
Referring again to the sole FIGURE, a solvent bath whose vapors are used to degrease workpieces placed within the degreasing apparatus is disposed within the boiling sump 14. Throughout the operation of the present apparatus as hereinafter described, compressor 26 continually compresses a refrigerant to a preselected high pressure while pumps 19 and 62 pump water or the like at a low pressure and constant rate through respective liquid loops 10 and 20 which conduct heat energy to the coils 14a to vaporize the solvent and to the coils 12a to condense the solvent vapors.
During a startup time period when no workpiece is present in the boiling sump 14, compressor 26 compresses a suitable refrigerant, such as Freon 12, which is conducted within the refrigerant loop 30. The compressor imparts its heat of compression to the refrigerant. The hot pressurized refrigerant discharged from the compressor 26 then flows through piping 26b and 24c to the condensing coils 24a disposed within the condenser 24. Within condenser 24, the hot pressurized refrigerant transfers its heat energy to the water pumped by pump 19 through the condenser space 25 of the condenser 24. The refrigerant is thereby condensed within the coils 24a. The temperature of the water within loop 10 begins to rise. The heat energy absorbed by the water in the condenser 24 is conducted through loop 10 to the heating coils 14a of the boiling sump 14. The temperature of the solvent thereby begins to rise. When sufficient heat is transfered from the refrigerant to the water the solvent in sump 14 will boil.
From the condensing coils 24a, the condensed refrigerant flows through piping 24b, through liquid refrigerant receiver 32, dryer 34, moisture indicator 36, piping 36b and 46c through the solenoid controlled valve 46 which is normally open. Valve 46 is controlled by the temperature responsive signal from the temperature sensor 58 disposed within liquid reservoir 60. The pressurized refrigerant then passes through thermal expansion valve 50 which suitably lowers the refrigerant pressure, evaporating coils 56a and return piping 27 to the compressor 26. The refrigerant absorbs heat energy from the ambient temperature water pumped through the loop 20 in the evaporator space 57 of the evaporator 56. Thus, the temperature of the water conducted through loop 20 including cooling coils 12a begins to decrease while the heated water pumped through the coils 14a of loop 10 dissipates its heat energy to the solvent bath thereby causing the solvent temperature to rise. The cooled water pumped through cooling coils 12a is available to condense the vapor once the solvent boils and vaporizes. Further, the water within loops 10 and 20 provides readily accessible heat energy to the refrigeration system and increases the energy efficiency of the present apparatus.
At the end of the startup time period, the solvent within the boiling sump 14 begins to boil and vaporize. As the vaporized solvent rises within the tank 11 and contacts the cooling coils 12a, the vapor is condensed by dissipating heat energy to the cooler water being conducted through the cooling coils 12a of loop 20. Lip 13 transports the condensed solvent to the sump 16. The heat energy absorbed by the water pumped through loop 20 is conducted to the evaporator space 57 of the evaporator 56 wherein the heat energy is absorbed by the low pressure refrigerant within the evaporating coils 56a prior to the refrigerant flowing through return piping 27 to the compressor 26. Compressor 26 imparts additional heat of compression or heat energy to the refrigerant.
The continuous adding of heat energy from the compressor 26 creates a condition of high temperature and pressure in the refrigerant loop 30 such that an amount of heat must be dissipated from the refrigerant in order to maintain a balanced system. Upon the occurrence of this high pressure condition within the refrigerant loop 30, pressure regulating valve 38 opens and allows an amount of refrigerant to flow through the auxiliary condenser branch 31 which dissipates the excess heat to the ambient atmosphere through the auxiliary condensing coils 40a. Constant speed fan 42 aids the heat dissipation. The remaining refrigerant which does not flow through branch 31 flows through the condensing coils 24a and the remainder of loop 30 to the compressor 26. Thus, the present apparatus reaches an equilibrium condition during which the solvent is continuously vaporized by the heating coils 14a and the vapors are continuously condensed by the cooling coils 12a disposed within the tank 11 while excess heat energy is dissipated to the ambient atmosphere via the refrigerant flow through the auxiliary condenser branch 31.
When a workpiece to be cleaned or degreased is placed into the boiling sump 14, a portion of the heat energy from the vapors is absorbed by the workpiece. That is, the solvent vapors condense on the workpiece and permit the water within loop 20 to absorb less heat energy thus lowering the temperature of the water within loop 20. This lowered water temperature produces a corresponding pressure drop within the refrigerant loop 30 and causes the preset pressure valve 38 to close commensurate with the lower pressure within the refrigerant loop. The introduction of additional workpieces causes valve 38 to close completely. Thus, heat energy formerly dissipated from the auxiliary condensing coils 40a to the ambient atmosphere is sufficiently retained within the refrigerant loop 30 of the present invention in order to maintain boiling of the solvent and the energy efficient thermodynamically balanced operation of the apparatus.
During heavy load conditions, the temperature of the water in loop 20 decreases to an even lower temperature. When the water decreases below a predetermined temperature, temperature sensor 58 generates a control signal to the solenoid valves 46 and 48, causing valve 46 to be closed and valve 48 to be opened. This allows refrigerant to flow through the auxiliary evaporator branch 33 and permits the refrigerant flowing through the auxiliary evaporating coils 54a to absorb the necessary heat energy from the ambient atmosphere in order to maintain a balanced system. Fan 42 rotates at constant speed and aids the absorption of heat energy by the refrigerant.
The above arrangement constitutes a safe and energy efficient vapor degreaser which utilizes a binary system and has the capability of efficiency absorbing or emitting heat energy to the ambient atmosphere when necessary to maintain a thermodynamic equilibrium for the desired operation of the degreaser.
While a plurality of chambers is shown in the preferred embodiment as hereinabove described, it is understood that a single chamber or sump may be used to vaporize and condense the solvent. It will also be apparent to those skilled in the art that other modifications may be made without departing from the broad principle and spirit of this invention which shall be limited only by the scope of the appended claim. | A vapor degreaser continually vaporizes and condenses a solvent bath and comprises two closed water loops associated with a refrigeration system. The water loops provide thermal storage for the degreaser and conduct heat to the solvent bath for heating the solvent and from the solvent vapors for condensing the vapors. The degreaser includes auxiliary heating and cooling coils which may be rendered totally inoperative when their operation is not energy efficient. | 5 |
BACKGROUND OF THE INVENTION
[0001] The present invention provides a high-pressure rotating swivel having an external cooling jacket fed by a portion of the operating fluid to allow use in high temperature environments.
SUMMARY OF THE INVENTION
[0002] Rotating waterjet nozzles for use in a high pressure (HP) range of approximately 1,000 to 40,000 psi and high fluid flow rates have become common maintenance tools used for cleaning, descaling or removing slag from industrial components such as furnaces, boilers and/or cookers. In order that maintenance can be done the most economical and efficient manner possible it is desirable to minimize the time in which any such equipment is not operational or is “offline.” Since such devices typically operate at high temperatures, significant time may be involved in allowing a device to cool to a suitable ambient temperature. Accordingly, it can be desirable to perform cleaning or maintenance while such devices are at or near operating temperature, or even during operation.
[0003] Fixed nozzles and lances are readily made entirely from metallic materials such as stainless steel which are suitable for use in high temperature environments but lack the benefit of a rotating nozzle to provide pattern of complete coverage of the surface being cleaned. The construction of a high pressure rotary swivel to provide a high pressure rotary waterjet nozzle has typically involved use of components which are not tolerant of operation at high temperatures. Such components such as shown in U.S. Pat. No. 6,059,202 to Zink, et al can include seals made from durable plastic, rubber or other similar materials which may be degraded or lose their beneficial physical properties when subjected to excessive heat. Other heat intolerant components can include lubricants, and viscous fluids which may be used for purposes such as speed control as shown in U.S. Pat. No. 5,964,414 to Hardy et al.
[0004] It is also well recognized that many of the high heat areas which are cleaned using waterjet tools, i.e. boiler tubes, are of small diameter or are accessed through passages of small diameter thereby requiring that the waterjet tools being used also be of small diameter. It is therefore desirable to minimize the thickness of any space or component which may add to the overall diameter of the tool.
[0005] Accordingly, in order to achieve the benefit of a high-pressure rotary swivel for use in a high temperature environment, the present invention provides for redirecting a small portion of the high pressure water or operating fluid into a space between the main body and thin-walled external jacket where it circulates at low pressure to absorb and dissipate heat thereby preventing overheating of the components of the swivel.
[0006] It is an object of the present invention to provide a high-pressure rotary waterjet nozzle or swivel assembly capable of operating in a high temperature environment.
[0007] It is another object of the present invention to provide a high-pressure rotary waterjet nozzle or swivel assembly capable of high temperature operation which is cooled using only the operating fluid.
[0008] It is another object of the present invention to provide a high-pressure rotary waterjet nozzle or swivel assembly capable of high temperature operation having a cooling circuit separate from the operating circuit, but using only a single source of fluid for both circuits.
[0009] It is another object of the present invention to provide a high-pressure rotary waterjet nozzle or swivel assembly capable of high temperature operation with a low pressure cooling circuit fed by the high-pressure operating fluid.
[0010] It is another object of the present invention to provide a high-pressure rotary waterjet nozzle or swivel assembly capable of high temperature operation with a low volume cooling circuit fed by the high-pressure operating fluid.
[0011] It is another object of the present invention to provide a high-pressure rotary waterjet nozzle or swivel assembly capable of operating in a high temperature environment where the body of the swivel is of small diameter.
[0012] It is an object of the present invention to provide for simple manufacture of a high-pressure rotary waterjet nozzle or swivel assembly capable of operating in a high temperature environment.
DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is a cross-section along the axis of the swivel of the preferred embodiment.
[0014] FIG. 2 is an exploded view of the swivel of the preferred embodiment showing the components of the swivel.
[0015] FIG. 3 is a cutaway perspective view of the swivel of the preferred embodiment showing the swivel assembly.
DETAILED DESCRIPTION OF THE INVENTION
[0016] As can be seen most clearly in FIG. 1 the cooled rotary nozzle assembly of the present invention is comprised of three primary components, a main body B, a rotary shaft A and an external sleeve C. Each of these primary components is constructed from any suitable material, typically a stainless steel.
[0017] It is to be understood that the invention described herein relates to the novel construction of an external cooling sleeve in conjunction with the main body and that the configuration of the rotary shaft with respect to the main body as described herein is merely representative. The present invention is readily adaptable to virtually any configuration of shaft and main body which might be chosen. In order to facilitate economical manufacturing of the cooling jacket structure, the required machining operations are largely limited to the exterior of the main body.
[0018] As described and illustrated herein the preferred embodiment is directed to cooling a swivel assembly in which the rotary shaft B is provided with a tapering spiral groove 14 and turns in a bath of a viscous lubricating fluid for speed control as shown in U.S. Pat. No. 5,964,414 to Hardy et al, which is incorporated herein by reference. Seals 12 at each end of the shaft retain the fluid and lubricant and prevent intrusion of contaminants.
[0019] For the intended high-temperature use of the present invention, a swivel assembly is typically attached using threaded connection or other suitable means to the end of a hollow tubular metallic lance or hose to provide a flow of high-pressure fluid into the inlet chamber 2 of the inlet nut 1 of the main body B. From chamber 2 the primary flow of operating fluid continues axially into and through the central bore 7 of the rotating shaft to the nozzle end 32 of the shaft were the fluid exits through a nozzle 33 fixed to the shaft end using a threaded connection 34 . The characteristics of the nozzle are determined by configuration of nozzle exit ports 35 chosen to provide appropriate self-rotation of the nozzle, a desired fluid volume and velocity and an appropriate cleaning pattern. The shaft is supported on bearings 11 suitable to allow rotation of the shaft relative to the body and the interface between the shaft and body is provided with a suitable high pressure rotary seal 10 to allow retention of the operating pressure of the swivel.
[0020] Inlet chamber 2 is further provided with one or more restrictive “bleed” passages or inlet orifices 3 to allow redirecting a small portion of the fluid through a passage or chamber 4 and 5 to an annular chamber 6 formed between the external sleeve C, and a circumferential recess machined on the outside of the main body. Fluid enters chamber 4 at relatively high velocity where its velocity is dissipated by being directed at a removable and replaceable plug 8 threaded into the main body.
[0021] As an example, when the total fluid flow passing through the swivel assembly may be about 60 gallons per minute, the flow diverted through by the bleed orifice(s) may be only about 1 to 2 gallons per minute. Additionally, the restrictive nature of the bleed orifices causes a pressure drop in the fluid from a many thousands of pounds per square inch (psi) to perhaps 100 psi, thereby allowing the external sleeve to be constructed using a relatively thin wall. The bleed orifice 3 and chamber 3 are readily created constructed by simply drilling holes of appropriate diameter from the outside of the main body. Each bleed orifice could also be made replaceable by being incorporated into a “thread-in” assembly in lieu of the separate plug 8 and orifice 3 .
[0022] Annular chamber 6 communicates with one or more substantially circumferential spiral or helical passages 20 defined by grooves or channels machined on the outside of the main body to evenly and fully cover the outer surface area of the main body B. The outer diameter of the main body B is precisely “press fit” within the inner diameter of external sleeve C so that spiral passages 20 are defined between the lands 21 of the spiral grooves, the outside of the main body and the inside of the external sleeve C. External sleeve C is further secured in place and sufficiently sealed by its opposite ends being seated against lips 9 of the main body. The inlet nut 1 of the main body is threaded into the main body with mating threads 15 and 15 ′ which secure the entire assembly together. Flow of operating fluid through these passages provides heat transfer to conduct the high ambient heat of the operating environment away from the components of the swivel. For reasons discussed above it may be desirable to limit the wall thickness of the external sleeve. However since the sleeve is evenly and fully supported by the external lands 21 of the main body, the durability of the sleeve is not significantly compromised by use of a thin-walled structure. While a spiral configuration of the passages is easily machined and is well suited to providing support of the external sleeve and controlled heat dissipation over substantially the entire surface of the main body, any configuration of a fluid pathway between the main body and external sleeve may be chosen so as to maximize any such characteristics which may be desirable.
[0023] Each spiral passage conducts a flow of operating fluid toward the outlet end of the assembly where each such passage communicates with another annular chamber 30 which, in turn, communicates with one or more exhaust ports 31 to allow the operating fluid from the cooling circuit to exit the swivel as waste. Since the volume of fluid flow through the cooling circuit is largely defined by restrictive nature of the inlet orifices, the exhaust ports need not be restrictive. However, as alternative configurations, the exhaust ports may be of a restrictive nature to either control flow through the cooling circuit or to allow the cooling circuit to be operated at high pressure with the exhaust ports providing additional fixed waterjets. | A high pressure rotary swivel assembly for use in high temperature environments using a single source of fluid for operation and cooling, having an external sleeve to accommodate a low volume and/or low pressure fluid cooling circuit having a path over the majority of the external surface of the swivel body to absorb ambient heat, where the cooling circuit is fed by redirecting a small portion of the high pressure and high volume operating fluid. | 5 |
This application is a divisional application of 09/560,738 filed Apr. 28, 2000 and now abandoned.
FIELD OF THE INVENTION
The present invention relates to magnetic elements for information storage and/or sensing and a fabricating method thereof, and more particularly, to a device and method of fabricating the magnetic element to include insulative veils.
BACKGROUND OF THE INVENTION
This application is related to a co-pending application that bears Motorola docket number CR97-133 and U.S. Ser. No. 09/144,686, entitled “MAGNETIC RANDOM ACCESS MEMORY AND FABRICATING METHOD THEREOF,” filed on Aug. 31, 1998, assigned to the same assignee and incorporated herein by this reference, co-pending application that bears Motorola docket number CR 97-158 and U.S. Ser. No. 08/986,764, entitled “PROCESS OF PATTERNING MAGNETIC FILMS” filed on Dec. 8, 1997, assigned to the same assignee and incorporated herein by this reference and issued U.S. Pat. No. 5,768,181, entitled “MAGNETIC DEVICE HAVING MULTI-LAYER WITH INSULATING AND CONDUCTIVE LAYERS”, issued Jun. 16, 1998, assigned to the same assignee and incorporated herein by.
Typically, a magnetic element, such as a magnetic memory element, has a structure that includes ferromagnetic layers separated by a non-magnetic layer. Information is stored as directions of magnetization vectors in magnetic layers. Magnetic vectors in one magnetic layer, for instance, are magnetically fixed or pinned, while the magnetization direction of the other magnetic layer is free to switch between the same and opposite directions that are called “parallel” and “anti-parallel” states, respectively. In response to parallel and anti-parallel states, the magnetic memory element represents two different resistances. The resistance has minimum and maximum values when the magnetization vectors of the two magnetic layers point in substantially the same and opposite directions, respectively. Accordingly, a detection of change in resistance allows a device, such as an MRAM device, to provide information stored in the magnetic memory element. The difference between the minimum and maximum resistance values, divided by the minimum resistance is known as the magnetoresistance ratio (MR).
An MRAM device integrates magnetic elements, more particularly magnetic memory elements, and other circuits, for example, a control circuit for magnetic memory elements, comparators for detecting states in a magnetic memory element, input/output circuits, etc. These circuits are fabricated in the process of CMOS (complementary metal-oxide semiconductor) technology in order to lower the power consumption of the device.
During typical magnetic element fabrication, such as MRAM element fabrication, metal films are grown by sputter deposition, evaporation, or epitaxy techniques. One such magnetic element structure includes a substrate, a base electrode multilayer stack, a synthetic antiferromagnetic (SAF) structure, an insulating tunnel barrier layer, and a top electrode stack. The base electrode layer stack is formed on the substrate and includes a first seed layer deposited on the substrate, a template layer formed on the seed layer, a layer of an antiferromagnetic material on the template layer and a pinned ferromagnetic layer formed on and exchange coupled with the underlying antiferromagnetic layer. The ferromagnetic layer is called the pinned layer because its magnetic moment (magnetization direction) is prevented from rotation in the presence of an applied magnetic field. The SAF structure includes a pinned ferromagnetic layer, and a fixed ferromagnetic layer, separated by a layer of ruthenium, or the like. The top electrode stack includes a free ferromagnetic layer and a protective layer formed on the free layer. The magnetic moment of the free ferromagnetic layer is not pinned by exchange coupling, and is thus free to rotate in the presence of applied magnetic fields.
During fabrication of these magnetic elements, ion milling is commonly used for the dry etching of the magnetic materials. However, during the process of dry etching, conducting veils are left remaining on the sides of the magnetic tunnel junction (MTJ). These remaining veils lead to electrical shorting of the device between the bottom and top electrodes, more particularly across the insulating tunnel barrier. Currently, wet etching techniques are used in the semiconductor industry to etch away the veils, but are not amenable for use in conjunction with magnetic materials due to their chemical attack on the magnetic materials leading to device performance degradation.
To avoid the shorting problem caused by veils, the current etching process is done in two steps. First the top magnetic layer of the magnetic element is etched or defined, then the whole stack is etched using a dry etch technique; or vice versa. Veils may be minimized by varying the etching beam angle relative to the wafer surface. Since the edges of the top and bottom magnetic layers do not overlap, the veils do not cause a shorting problem between the top and bottom magnetic layers. However, this is a very complex etching process. Stopping the etch of the top magnetic layer without over-etching through the ultra thin tunnel barrier, and into the bottom magnetic layer is very difficult to do. Over-etching into the bottom magnetic layer will cause unwanted magnetic poles shifting the resistance-magnetic field response of the magnetic element. This technique also limits the free magnetic layer to be placed on top of the tunnel barrier.
Accordingly, it is a purpose of the present invention to provide for a magnetic element having formed as a part thereof, insulating veils, which no longer include conductive or magnetic properties.
It is a still further purpose of the present invention to provide a method of forming a magnetic element with insulating veils.
It is another purpose of the present invention to provide a method of fabricating a magnetic element that includes plasma oxygen ashing of the magnetic stack to transform conducting veils into insulating veils.
It is another purpose of the present invention to provide a method of forming a magnetic element with insulating veils which is amenable to simple and high throughput manufacturing.
It is still a further purpose of the present invention to provide a method of forming a magnetic element with insulating veils that allows for the formation of the free magnetic layer anywhere within the magnetic element stack.
SUMMARY OF THE INVENTION
These needs and others are substantially met through provision of a magnetic element including a base metal layer, a first electrode, a second electrode and a spacer layer. The base metal layer is positioned on an uppermost surface of a substrate element. A spacer layer is located between the ferromagnetic layers for permitting tunneling current in a direction generally perpendicular to the ferromagnetic layers. In an alternative embodiment, the structure is described as including a SAF structure to allow for proper balancing of magnetostatic interaction in the magnetic element. The device includes insulative veils characterized as electrically isolating the first electrode and the second electrode, the insulative veils including non-magnetic and insulating dielectric properties. Additionally disclosed is a method of fabricating the magnetic element with insulative veils that have been transformed from having conductive properties to having insulative properties through oxygen plasma ashing techniques.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1-3 illustrate in cross-sectional views, the steps in fabricating a magnetic element with insulative veils according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
During the course of this description, like numbers are used to identify like elements according to the different figures that illustrate the invention. FIGS. 1-3 illustrate in cross-sectional views a magnetic element according to the present invention. More particularly, illustrated in FIG. 1, is a first step in the fabrication of a patterned magnetic element 10 . Illustrated in FIG. 1, is a fully patterned magnetic element structure 10 . The structure includes a substrate 12 , a first electrode multilayer stack 14 , a spacer layer 16 including oxidized aluminum, and a second electrode multilayer stack 18 . It should be understood that spacer layer 16 is formed dependent upon the type of magnetic element being fabricated. More particularly, in a MTJ structure, spacer layer 16 is formed of a dielectric material, and in a spin valve structure, spacer layer 16 is formed of a conductive material. First electrode multilayer stack 14 and second electrode multilayer stack 18 include ferromagnetic layers. First electrode layers 14 are formed on a base metal layer 13 , which is formed on substrate 12 . Base metal layer 13 is disclosed as composed of a single metal material or layer or a stack of more than one metal material or layer. First electrode layer 14 includes a first seed layer 20 , deposited on base metal layer 13 , a template layer 22 , a layer of antiferromagnetic pinning material 24 , and a fixed ferromagnetic layer 26 formed on and exchange coupled with the underlying antiferromagnetic pinning layer 24 . It should be understood that anticipated by this disclosure is a pseudo spin-valve structure that would not include the antiferromagnetic pinning layer. In this instance, the pseudo spin-valve structure would include a first electrode and a second electrode including a first switching field and a second switching field thereby defining the pseudo spin-valve structure.
Typically, seed layer 20 is formed of tantalum nitride (TaNx) having template layer 22 formed thereon. Template layer 22 in this particular embodiment is formed of ruthenium (Ru). Pinning layer 24 is typically formed of iridium manganese (IrMn).
In this particular embodiment, ferromagnetic layer 26 is described as fixed, or pinned, in that its magnetic moment is prevented from rotation in the presence of an applied magnetic field. Ferromagnetic layer 26 is typically formed of alloys of one or more of the following: nickel (Ni), iron (Fe), and cobalt (Co).
Second electrode stack 18 includes a free ferromagnetic layer 28 and a protective contact layer 30 . The magnetic moment of the free ferromagnetic layer 28 is not fixed, or pinned, by exchange coupling, and is free to rotate in the presence of an applied magnetic field. Free ferromagnetic layer 28 is typically formed of a nickel iron (NiFe) alloy or a nickel iron cobalt (NiFeCo) alloy. It should be understood that a reversed, or flipped, structure is anticipated by this disclosure. More particularly, it is anticipated that the disclosed magnetic element can be formed to include a top fixed, or pinned layer, and thus described as a top pinned structure. In addition, a device including dual spacer layers is anticipated by this structure. In this instance, magnetic element 10 would structurally include a bottom pinned magnetic layer, a bottom spacer, or tunnel barrier layer, a free magnetic layer, a top spacer, or tunnel barrier layer, and a top pinned magnetic layer. The bottom pinned magnetic layer, the free magnetic layer and the top pinned magnetic layer include ferromagnetic layers. The bottom magnetic layer is optionally formed on a diffusion barrier layer which is formed on a metal lead which in turn is typically formed on some type of dielectric materal. The diffusion barrier layer is typically formed of tantalum nitride (TaN), and aids in the thermal stability of the magnetic element.
Fixed ferromagnetic layer 26 is described as pinned, or fixed, in that its magnetic moment is prevented from rotation in the presence of an applied magnetic field. Ferromagnetic layer 26 as previously stated is typically formed of alloys of one or more of the following: nickel (Ni), iron (Fe), and cobalt (Co). Magnetic layer 28 is described as a free ferromagnetic layer. Accordingly, the magnetic moment of free ferromagnetic layer 28 is not fixed, or pinned, by exchange coupling, and is free to rotate in the presence of an applied magnetic field. Free ferromagnetic layer 28 is formed co-linear with fixed magnetic layer 26 and of alloys of one or more of the following: nickel (Ni), iron (Fe), and cobalt (Co). Fixed ferromagnetic layer 26 is described as having a thickness within a range of 5-500 Å. Free ferromagnetic layer 28 is described as having a thickness generally in the range of 5-500 Å.
In this particular embodiment, spacer layer 16 is formed of aluminum (Al) and oxygen (O). More particularly, spacer layer 16 is formed having a general formula of AlO x , where 0<x≦1.5. It should be understood that when device 10 includes dual spacer layers, as previously discussed, that the second spacer layer would be formed of oxidized tantalum (Ta), generally having the formula TaO x , where 0<x≦2.5.
Illustrated in FIG. 2, the next step in the method of fabricating device 10 according to the present invention. More particularly, as illustrated, the plurality of epitaxially deposited layers are etched to define device 10 having included as a part thereof conductive veils 32 . Conductive veils 32 are formed subsequent to ion milling or reactive ion etching which is utilized to form device 10 . Conductive veils 32 provide an electrical path between first electrode 14 and second electrode 18 and thereby cause device 10 to fail, due to the shorting out of the device across insulative spacer layer 16 . Typically these veils are etched off utilizing a wet etch process, which causes degraded device performance, and thus not suitable for MRAM device fabrication. In addition, wet etching away conductive veils 32 is hard to utilize for deep submicron features, results in a non-uniform lateral over-etch, causing switching fields to vary, and results in an inability to make every cell the same shape and having the same switching field.
Referring now to FIG. 3, illustrated is the next step in the method of fabricating device 10 according to the present invention. More particularly, as illustrated, conductive veils 32 are next dry etched, using oxygen plasma ashing at either room temperature, more particularly at temperature of 150° C., or a higher temperature. This oxygen plasma etching of conductive veils 32 provides for the transformation of conductive veils 32 into insulative veils 34 . Insulative veils 34 are thus described as inactive having non-magnetic, dielectric properties. The fabrication of insulative veils 32 results in a device having electrically isolated, first electrode 14 and second electrode 18 .
It should be understood that due to the ability to electrically isolate first electrode 14 and second electrode 18 , that free magnetic layer 28 can be formed anywhere in device 10 . Prior art dictates the fabrication of the free magnetic layer on the top of the device stack due to its fabrication as a thin layer, and the ability to turn portions of it into a dielectric material, thus electrically isolating the electrodes. This transformation of the thin free magnetic layer as disclosed and claimed herein provides for the blocking of the conduction path through the naturally formed conductive veil between the first electrode and the second electrode. In this particular invention, in that the conductive veils have been transformed into insulative veils 34 , free magnetic layer 28 can be formed anywhere in the device stack. It should be understood that it is anticipated by this disclosure that device 10 may include a synthetic antiferromagnetic (SAF) structure that is formed between two tunnel barrier, or spacer, layers, or alternatively below a first spacer or tunnel barrier layer, or on a surface of a top spacer or tunnel barrier layer.
Thus, a magnetic element with insulative veils and fabricating method thereof is disclosed in which the device structure and method of fabricating the device is improved based on the transformation of conductive veils to insulative veils. As disclosed, this technique can be applied to devices using patterned magnetic elements, such as magnetic sensors, magnetic recording heads, magnetic recording media, or the like. Accordingly, such instances are intended to be covered by this disclosure | An improved and novel device and fabrication method for a magnetic element, and more particularly a magnetic element ( 10 ) including a first electrode ( 14 ), a second electrode ( 18 ) and a spacer layer ( 16 ). The first electrode ( 14 ) and the second electrode ( 18 ) include ferromagnetic layers ( 26 & 28 ). A spacer layer ( 16 ) is located between the ferromagnetic layer ( 26 ) of the first electrode ( 14 ) and the ferromagnetic layer ( 28 ) of the second electrode ( 16 ) for permitting tunneling current in a direction generally perpendicular to the ferromagnetic layers ( 26 & 28 ). The device includes insulative veils ( 34 ) characterized as electrically isolating the first electrode ( 14 ) and the second electrode ( 18 ), the insulative veils ( 34 ) including non-magnetic and insulating dielectric properties. Additionally disclosed is a method of fabricating the magnetic element ( 10 ) with insulative veils ( 34 ) that have been transformed from having conductive properties to insulative properties through oxygen plasma ashing techniques. | 7 |
BACKGROUND
[0001] 1. Technical Field
[0002] The present disclosure relates generally to a lens module and an image pick-up apparatus incorporating the lens module.
[0003] 2. Description of Related Art
[0004] Many image pick-up apparatuses are used in a variety of consumer electronic devices, such as notebook computers, personal digital assistants (PDAs), and cellular telephones. There is an increasing demand for better image quality, which essentially depends on the quality of the lens module of the image pick-up apparatus. That is, a lens module with a high image quality is desired.
[0005] Referring now to FIG. 6 , a lens module 15 used in an image pick-up apparatus includes a light shielding plate 11 and two lenses 151 , 152 . The two lenses 151 and 152 are aligned with each other, and the light shielding plate 11 is sandwiched between and aligned with the two lenses 151 and 152 . The light shielding plate 11 defines a cylindrical through hole 15 A at the center thereof for allowing the passage of light, and has an inner side face 150 in the through hole 15 A. The light shielding plate 11 is for absorbing light which falls thereon, thereby eliminating the stray light in the lens module 15 . In other words, glare in the lens module 15 is eliminated. When the light through the lens module 15 is very strong, the inner side face 150 of the light shielding plate 11 in the through hole 15 A cannot completely prevent the stray light, and reflects some of the light onto the image sensor of an image pick-up apparatus incorporating the lens module 15 . This will influence the imaging quality of the image pick-up apparatus incorporating the lens module 10 .
[0006] Therefore, there is a need for a lens module and an image pick-up apparatus, to overcome the above mentioned limitations.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] Many aspects of the present embodiments can be better understood with reference to the following drawings. The components in the drawings are not necessarily drawn to scale, the emphasis instead being placed upon clearly illustrating the principles of the present embodiments. Moreover, in the drawings, like reference numerals designate corresponding parts throughout the views.
[0008] FIG. 1 is a sectional view of a light shielding plate according to a first exemplary embodiment.
[0009] FIG. 2 is a sectional view of a light shielding plate according to a second exemplary embodiment.
[0010] FIG. 3 is a sectional view of a light shielding plate according to a third exemplary embodiment.
[0011] FIG. 4 is a sectional view of an image pick-up apparatus comprising the light shielding plates of FIGS. 1 and 2 , according to a fourth exemplary embodiment.
[0012] FIG. 5 is a sectional view of a lens module comprising the light shielding plate of FIG. 3 , according to a fifth exemplary embodiment.
[0013] FIG. 6 is a sectional view of a related art of a lens module.
DETAILED DESCRIPTION
[0014] Referring to FIG. 1 , a light shielding plate 10 in accordance with a first exemplary embodiment is a round disk. The light shielding plate 10 has a first surface 10 A and a second surface 10 B facing away from the first surface 10 A. The light shielding plate 10 defines a through hole 10 C at the center thereof and through the first and second surfaces 10 A and 10 B. The through hole 10 C tapers from the first surface 10 A to the second surface 10 B, thereby forming a small section of a shallow cone (conical surface 101 ) in the through hole 10 C. The conical surface 101 is interconnected between the first surface 10 A and the second surface 10 B. In an alternative embodiment, the light shielding plate 10 can also be rectangular. The thickness of the light shielding plate 10 is in the range from about 0.030 mm to about 0.054 mm.
[0015] Referring to FIG. 2 , a light shielding plate 20 in accordance with a second exemplary embodiment is also a round disk. The light shielding plate 20 has a third surface 20 A and a fourth surface 20 B facing away from the third surface 20 A. The light shielding plate 20 defines a through hole 20 C at the center thereof and through the third and fourth surfaces 20 A and 20 B. The through hole 20 C tapers from the fourth surface 20 B to the third surface 20 A, thereby forming a conical surface 201 in the through hole 20 C. The conical surface 201 is interconnected between the third surface 20 A and the fourth surface 20 B. The light shielding plate 20 has an outer diameter and a thickness greater than those of the light shielding plate 10 . In an alternative embodiment, the light shielding plate 20 can also be rectangular.
[0016] Referring to FIG. 3 , a light shielding plate 30 in accordance with a third exemplary embodiment is also a round disk. The light shielding plate 30 has a fifth surface 30 A and a sixth surface 30 B facing away from the fifth surface 30 A. The light shielding plate 30 defines a through hole 30 C at the center thereof and through the fifth surface 30 A and the sixth surface 30 B. The through hole 30 C includes a first hole portion 30 CA adjacent to the fifth surface 30 A, and a second hole portion 30 CB adjacent to the sixth surface 30 B. The first hole portion 30 CA and the second hole portion 30 CB are aligned with and in communication with each other, so as to create (in section) an internal knife edge. An imaginary interface 30 CC between the first hole portion 30 CA and the second hole portion 30 CB is formed between the fifth surface 30 A and the sixth surface 30 B. The first hole portion 30 CA tapers from the fifth surface 30 A to the interface 30 CC, and the second hole portion 30 CB tapers from sixth surface 30 B to the interface 30 CC. Thus, a first conical surface 301 is defined in the first hole portion 30 CA, and the second conical surface 302 is defined in the second hole portion 30 CB. The first conical surface 301 and the second conical surface 302 intersect at a common line in the interface 30 CC.
[0017] Referring to FIG. 4 , an image pick-up apparatus 100 in accordance with a fourth exemplary embodiment includes the light shielding plate 10 , the light shielding plate 20 , a lens barrel 33 , a first lens 40 , a second lens 50 , a third lens 60 , an infrared filter 70 , a holder 80 , and an image sensor 90 . The lens barrel 33 has a first end face 311 and an opposite second end face 312 . A light passing hole 313 is defined in the first end face 311 , and a receiving hole 314 is defined in the second end face 312 . The light passing hole 313 is conical in section and tapers away from the first end face 311 . The receiving hole 314 is cylindrical. The light passing hole 313 is in communication with the receiving hole 314 , thereby forming an interface 315 between the light passing hole 313 and the receiving hole 314 . The light passing hole 313 at the interface 315 has a diameter less than that of the receiving hole 314 . Thus, the interface 315 faces toward the receiving hole 314 . The light passing hole 313 allows ambient light to enter into the receiving hole 314 . The receiving hole 314 receives the light shielding plate 10 , the light shielding plate 20 , the first lens 40 , the second lens 50 , the third lens 60 , and the Infrared filter 70 . The lens barrel 33 has an outer thread 330 on the surface adjacent to the second end face 312 .
[0018] In this embodiment, the first, second and third lenses 40 , 50 , and 60 are plastic. The first lens 40 is adjacent to the first end face 311 , the third lens 60 is adjacent to the second face 312 , and the second lens 50 is between the first lens 40 and the third lens 60 . The first, second and third lenses 40 , 50 , and 60 focus light entering the light passing hole 313 onto the image sensor 90 .
[0019] The first lens 40 includes a central round portion 402 and a peripheral stepped structure 404 . The peripheral stepped structure includes a radially extending portion 406 surrounding the central round portion 402 , and an axially extending portion 408 extending axially from the radially extending portion 406 toward the second lens 50 . The peripheral stepped structure 404 has an inward-facing surface 410 and a conical side face 412 . The inward-facing surface 410 belongs to the radially extending portion 406 , and is adjacent to the central round portion 402 . The conical side face 412 belongs to the axially extending portion 408 , and is adjacent to the inward-facing surface 410 . The conical side face 412 is inclined in a direction away from the central round portion 402 .
[0020] The second lens 50 includes a central round portion 502 and a peripheral portion 504 surrounding the second central round portion 502 . The peripheral portion 504 has an outward-facing surface 506 adjacent to the second central round portion 502 , and a conical side face 508 adjacent to the outward-facing surface 506 . The conical side face 508 extends inwards from the out-facing surface 506 , and is inclined in a direction away from the second central round portion 502 . The inclined angle between the outward-facing surface 506 and the conical side face 508 is the same as that between the inward-facing surface 410 and the conical side face 412 .
[0021] The third lens 60 includes a central round portion 602 and a peripheral portion 604 surrounding the second central round portion 602 . The Infrared filter 70 filters IR light at this point.
[0022] The first lens 40 , the second lens 50 , the third lens 60 and the Infrared filter 70 are received in the receiving hole 314 from the first end face 311 to the second end face 312 in the order described. The second lens 50 engages with the first lens 40 in such a way that the conical side face 508 contacts the conical side face 412 , and the inward-facing surface 410 faces and is parallel with the outward-facing surface 506 . The light shielding plate 10 is arranged between the inward-facing surface 410 and the outward-facing surface 506 in such a manner that the first surface 10 A contacts the inward-facing surface 410 and the second surface 10 B contacts the outward-facing surface 506 . The through hole 10 C is aligned with the central round portions 402 and 502 . The second light shielding plate 20 is arranged between the second lens 50 and the third lens 60 in such a manner that the peripheral portion 504 is in contact with the third surface 20 A and the peripheral portion 604 is in contact with the fourth surface 20 B. The Infrared filter 70 is in contact with the peripheral portion 604 of the third lens 60 .
[0023] The holder 80 includes a cylindrical connection portion 80 A and a receiving portion 80 B. The connection portion 80 A defines a cylindrical through hole 85 and an interior thread 85 A in the through hole 85 . The interior thread 85 A is in threaded engagement with the outer thread 330 . The receiving portion 80 B extends axially from the end of the connection portion 80 A away from the lens barrel 33 . The receiving portion 80 B defines a through hole 87 in communication with the through hole 85 . The image pick-up apparatus 100 further includes a printed circuit board 95 fixed to the end of the receiving portion 80 B away from the connection portion 80 A and capping the through hole 87 .
[0024] The image sensor 90 can be a charge-coupled device (CCD) or a complementary metal-oxide-semiconductor (CMOS). The image sensor 90 is arranged on and electrically connected with the printed circuit board 95 . The image sensor 90 is received in the through hole 87 , and faces the Infrared filter 70 . The image sensor 90 is optically coupled with the first lens 40 , the second lens 50 , the third lens 60 and the Infrared filter 70 .
[0025] In this embodiment, because the conical surface 101 is inclined toward the first end face 311 , the conical surface 101 can reflect some of the light entering the light passing hole 313 away from the image sensor. Furthermore, the conical surface 201 is inclined away from the first end face 311 , thus any light which does not fall directly through the light passing hole 313 can reach the conical surface 201 . Thus, any glare in the image pick-up apparatus 10 is effectively reduced.
[0026] In alternative embodiments, the locations of the light shielding plates 10 and 20 can be exchanged. The number of the lenses in the image pick-up apparatus 100 may vary.
[0027] Referring to FIG. 5 , an image pick-up apparatus 200 in accordance with a fifth exemplary embodiment is similar to the image pick-up apparatus 100 of the fourth exemplary embodiment. The distinguishing features are that the light shielding plate 30 is between the second lens 50 and the third lens 60 , instead of the square-edged light shielding plate 11 . The through hole 15 A of the light shielding plate 11 has a diameter greater than that of the interface 30 CC of the light shielding plate 30 . The first conical surface 301 of the light shielding plate 30 has the same function as that of the conical surface 101 in the image pick-up apparatus 100 , and the second conical surface 302 of the light shielding plate 30 has the same function as that of the conical surface 201 in the image pick-up apparatus 100 .
[0028] It is believed that the present embodiments and their advantages will be understood from the foregoing description, and it will be apparent that various changes may be made thereto without departing from the spirit and scope of the disclosure or sacrificing all of its material advantages, the examples hereinbefore described merely being preferred or exemplary embodiments of the disclosure. | A lens module includes a lens barrel, two lenses, and a light shielding plate. The lens barrel has a light passing hole and a receiving hole in communication with the light passing hole. The lenses are received in the receiving hole and aligned with the light passing hole and aligned with the light passing hole. The light shielding plate is arranged between the two lenses. The conic section of the light shielding plate prevents unwanted or stray light from reaching the image sensor. | 6 |
This is a division of application Ser. No. 07/701,407 filed May 14, 1991.
TECHNICAL FIELD OF THE INVENTION
The present invention relates to the field of substituted styrenes and, more particularly, to a process for the preparation thereof from bisarylalkyl ethers and a process for the preparation of such bisarylalkyl ethers from arylalkanols. Still more particularly, the present invention discloses a method of preparing 4-acetoxystyrene and 4-methoxystyrene from 4,4'-(oxydiethylidene)bisphenol diacetate, and 4,4'-(oxydiethylidene)bisphenol dimethyl ether, respectively. Furthermore, the present invention discloses a method of preparing 4,4'-(oxydiethylidene)bisphenol diacetate and 4,4-(oxydiethylidene)bisphenol dimethyl ether from 4-acetoxyphenylmethylcarbinol and 4-methoxyphenylmethylcarbinol, respectively.
BACKGROUND OF THE INVENTION
Substituted styrenes are known compounds which are used in the production of photoresists, adhesives, coating compositions, pharmaceuticals, ultraviolet-absorbing sunscreen agents and other like compounds. More particularly, they are used as intermediate monomers for the production of polymers used for the preparation of said compounds.
A well known substituted styrene compound is 4-acetoxystyrene. The monomer 4-acetoxystyrene is a stable monomer which can be readily polymerized and copolymerized to low, medium and high molecular weight polymers. The monomer readily polymerizes in solution, suspension, emulsion or bulk using well-known free radical catalysts such as, for example, the peroxide and azo compounds. Such polymerization can take place in the absence of comonomers whereby the resultant product is a homopolymer or in the presence of comonomers whereby the resultant product is a copolymer. Examples of processes used for the production of homopolymers or copolymers of 4-acetoxystyrene are the processes disclosed in U.S. Pat. Nos. 4,822,862, 4,912,173 and 4,962,147. Other well-known processes can also be used.
In the case of copolymerization, the most commonly used comonomer is styrene. Other comonomers include vinyltoluene; alpha-methylstyrene; ortho-, meta-, and para- cloro- and bromostyrene; the diene monomers such as butadiene, the acrylate and methacrylate ester monomers such as methyl acrylate, ethyl acrylate, butyl acrylate, butyl methacrylate and 2-ethylhexyl acrylate; acrylonitrile; methacrylonitrile; the polymerizable acids such as acrylic acid, methacrylic acid, maleic acid, fumaric acid and the like; and the allyl ester comonomers described in U.S. Pat. No. 4,877,843. The homopolymers and the copolymers of 4-acetoxystyrene can be hydrolyzed to produce homopolymers and copolymers of 4-hydroxystyrene which are well-known compositions used in the manufacturing of metal treatment compositions, photoresists, epoxy resins and epoxy resin curing agents. Processes for the conversion of homopolymers and copolymers of 4-acetoxystyrene to homopolymers and copolymers of 4-hydroxystyrene are disclosed in U.S. Pat. Nos. 4,678,843, 4,689,371, 4,822,862, 4,857,601, 4,877,843, 4,898,916, 4,912,173, and 4,962,147.
Several methods have been developed for the production of the monomer 4-acetoxystyrene. Corson, et al., Preparation of Vinylphenols and Isopropenylphenols, 23 J. Org. Chem. 544-549 (1958), discloses a process for making 4-acetoxystyrene from phenol. According to the process, phenol is acylated to 4-hydroxyacetophenone which is then acetylated to 4-acetoxyacetophenone. The latter compound is hydrogenated to 4-acetoxyphenylmethylcarbinol, which is, then, dehydrated to 4-acetoxystyrene. Another process for the preparation of 4-acetoxystyrene is disclosed in copending U.S. patent application Ser. No. 07/548,170, now U.S. Pat. No. 5,041,614, which is incorporated herein and is made part hereof by reference. In that process, 4-acetoxyphenylmethylcarbinol is dehydrated in the presence of acetic anhydride and an acid catalyst to form 4-acetoxystyrene. The compound 4-acetoxyphenylmethylcarbinol is sometimes referred to herein for brevity and convenience as "APMC."
Copending U.S. patent application Ser. No. 07/598,510, now U.S. Pat. No. 5,151,546, discloses methods of preparing APMC. One method involves heating 4-acetoxyacetophenone at a temperature of from about 54° C. to about 120° C. and at a pressure of about 14.7 psig to about 5000 psig in the presence of at least a stoichiometric amount of hydrogen and a catalyst selected from the group consisting of Pd/C or activated nickel in the absence of a solvent. Another method involves the hydrogenation of 4-acetoxyacetophenone with a suitable reagent such as NaBH 4 , lithium aluminum hydride, hydrogen and diisobutyl aluminum hydride in the presence of a solvent.
Another method of preparing 4-acetoxystyrene is disclosed in copending U.S. patent application Ser. No. 07/598,510 which is incorporated herein and is made part hereof by reference. APMC is dehydrated in the presence of a dehydrating agent such as KHSO 4 , alumina, titania, silica gel and mineral acids. The reaction is carried out under substmospheric conditions at a temperature in the range of 85° C. to 300° C. for about 0.2 to about 10 minutes.
Examples of other substituted styrene derivatives are disclosed in U.S. Pat. Nos. 4,868,256; 4,868,257; 4,933,495; 4,927,956 and 4,965,400. U.S. Pat. Nos. 4,868,256; 4,868,257 and 4,933,495 disclose methods for producing substituted styrenes and, more particularly, 3-mono or 3,5-disubstituted acetoxystyrene by dehydrating 1-(3'-mono or 3',5'-disubstituted-4'-acetoxyphenyl) ethanol with an acid or a base and hydrolyzing said product to produce 3-mono or 3,5-disubstituted hydroxystyrene. The substituents are selected from the group consisting of Cl, Br, I, NO 2 , NH 2 , SO 3 H or C 1 -C 10 alkyl. Furthermore, those patents disclose a method of producing 3-bromo-4-acetoxy-5-methylstyrene from 1-(3'-bromo-4'-acetoxy-5'-methylphenyl)ethanol.
U.S. Pat. No. 4,927,956 discloses 3,5-disubstituted-4-acetoxystyrene wherein the substitution is independently C 1 to C 10 alkyl or alkoxy or amino; and substituted 4-hydroxy- and 4-acetoxystyrene compounds wherein the substitutes in the 2,3 and 6- positions are independently hydrogen, alkyl, alkoxy or halogen and the substitute in the 5-position is chlorine or bromine.
U.S. Pat. No. 4,965,400 is directed to a method of preparing 3,5-disubstituted-4-acetoxystyrene by dehydrating 1-(3',5'-disubstituted-4'-acetoxyphenyl)ethanol wherein each of the 3,5-substitutions are independently C 1 to C 10 alkyl or alkoxy, amino or halogen. The reaction is carried out in the presence of an acid dehydrating agent.
Although several methods were employed in the past for the preparation of substituted styrenes, none of those methods involved the preparation of such substituted styrenes from bisarylalkyl ethers such as 4,4'-(oxydiethylidene)-bisphenol diacetate or 4,4'-(oxydiethylidene)bisphenol dimethyl ether.
4,4'-(oxydiethylidene)bisphenol diacetate which is otherwise identified as bis (4-acetoxyphenylmethylcarbinol) ether is sometimes referred to herein for brevity and convenience as "APMC-Ether." The compound 4,4'-(oxydiethylidene)bisphenol dimethyl ether which is otherwise identified as (4-methyoxyphenylmethylcarbinol) ether is sometimes referred to herein for brevity and convenience as "MPMC-Ether."
APMC-Ether is a compound isolated from a species of mushrooms as disclosed in F. Bohlmann et al., Phytochemistry 18(8), 1403 (1979). Furthermore, APMC-Ether is formed as an impurity in the acid catalyzed dehydration of APMC to 4-acetoxystyrene monomer and in the thermal treatment of APMC during its purification.
In the past, there were no uses for APMC-Ether, Accordingly, APMC-Ether removed from mixtures containing it as an impurity required disposal in landfills or similar disposal sites thereby giving rise to economic and environmental burdens. According to the present invention, APMC-Ether is used to produce 4-acetoxystyrene whereby the aforesaid economic and environmental burdens are eliminated.
In addition to disclosing a method of preparing substituted styrene derivatives from bisarylalkyl ethers, the present invention discloses a method of preparing such bisarylalkyl ethers from corresponding arylalkanols. Such method is preferably used for the preparation of APMC-Ether from APMC and for the preparation of MPMC-Ether from 4-methoxyphenylcarbinol which is sometimes referred to herein for brevity and convenience as "MPMC." No such method was disclosed by the prior art.
These and other advantages of the present invention will become apparent from the following description.
SUMMARY OF THE INVENTION
A bisarylalkyl ether such as APMC-Ether or MPMC-Ether is heated in the presence of an acid catalyst to produce a substituted styrene such as 4-acetoxystyrene or 4-methoxystyrene, respectively. The reactant which is in the liquid phase is heated to a temperature of about 160° C. to about 230° C. to convert the bisarylalkyl ether to the substituted styrene by cleavage and dehydration. The reaction is preferably carried out under subatmospheric conditions to effect the immediate vaporization and removal of the substituted styrene product from the reactor to prevent the polymerization of such product. The reaction is carried out preferably in the presence of a free radical inhibitor which inhibits the free radical polymerization of the substituted styrene product. In the case of the preparation of 4-acetoxystyrene from APMC-Ether, the reaction is preferably carried out also in the presence of acetic anhydride to prevent the hydrolysis of 4-acetoxystyrene to 4-hydroxystyrene.
A method of preparing a bisarylalkyl ether from a corresponding arylalkanol through the condensation of the arylalkanol in the presence of an acid catalyst is also disclosed. Such method is preferably used for the preparation of APMC-Ether from APMC and for the preparation of MPMC-Ether from MPMC. The arylalkanol reactant is heated to a temperature of about 80° C. to about 120° C. in the presence of the catalyst. The reaction is preferably carried out under subatmospheric pressure to effect the rapid removal of the water coproduct of the reaction. Such removal causes an increase in the yield and selectivity to the bisarylalkyl ether.
DETAILED DESCRIPTION OF THE INVENTION
(a) Preparation of Substituted Styrenes from Bisarylalkyl Ethers
According to the present invention, a process for the production of a substituted styrene is disclosed by heating a bisarylalkyl ether in the presence of an acid catalyst. One equivalent of the bisarylalkyl ether is cleaved and dehydrated to produce two equivalents of substituted styrene. The substituted styrene produced in accordance of the present invention is of the formula: ##STR1## wherein R 1 is ##STR2## --O--CH 3 , --O--CH 2 --CH 3 , halogen or NO 2 ; and R 2 , R 3 , R 4 and R 5 are independently hydrogen, halogen or C 1 -C 4 alkyl.
The reactant bisarylalkyl ether is of the formula (Formula 2), ##STR3## wherein R 1 is ##STR4## --O--CH 3 , --O--CH 2 --CH 3 , halogen or NO 2 ; and R 2 , R 3 , R 4 and R 5 are independently hydrogen, halogen, or C 1 -C 4 alkyl.
The reactant bisarylalkyl ether in its liquid phase is fed to a reactor. Therein, in the presence of the acid catalyst, it is heated to a temperature which is sufficiently high to effect the cleavage and dehydration of the reactant to form the substituted styrene but sufficiently low to minimize the tendency of the components of the reaction mass for polymerization. Accordingly, the reaction is carried out at temperatures in the range of about 120° C. to about 230° C. and, preferably, in the range of about 160° C. to about 220° C. The reaction mass is continuously stirred by well known stirring means to maintain the homogeneity thereof.
Because the substituted product readily polymerizes under the temperature conditions encountered in the reaction, it is preferred that the product be removed immediately from the reaction mass via evaporation. Accordingly, the reaction is carried out under subatmospheric conditions, preferably in the range of about 0.5 mm Hg to about 100 mm Hg, to effect the immediate vaporization and removal of the product from the reaction mass. The vaporized product is cooled and condensed in a condenser and is collected as a liquid product in an overhead receiver.
The conversion of the bisarylalkyl ether to substituted styrene in accordance with the present invention is relatively fast. In the case of the conversion of APMC-Ether, for example, the conversion typically takes place in about less than one second to about 15 minutes depending on feed rate to the reactor, mixing conditions and temperature.
The reaction may be carried out in a batch mode, a continuous mode or a combination thereof such as a continuous fed-batch mode. In the continuous fed-batch mode, reactant and catalyst are continuously fed to the reactor, the substituted styrene product is continuously removed by evaporation and the residue and the catalyst are allowed to build up in the reactor until the end of the cycle.
Any one of the acid catalysts may be used to carry out the reaction of the present invention. Such catalysts include, but are not limited to, phosphoric acid, p-toluenesulfonic acid, methanesulfonic acid, ammonium bisulfate and potassium bisulfate. The amount of catalyst required varies from catalyst to catalyst. In all instances, however, the amount is very small as compared to the amount of reactant. In the case of the conversion of APMC-Ether to 4-acetoxystyrene, for example, the amount of catalyst is usually less that one (1) mole of catalyst per 100 moles of reactant APMC-Ether.
In accordance with the present invention, the reaction is typically carried out stoichiometrically as follows (Reaction 1): ##STR5## wherein R 1 is ##STR6## --O--CH 3 , --O--CH 2 --CH 3 , halogen or NO 2 ; and R 2 , R 3 , R 4 and R 5 are independently hydrogen or C 1 -C 4 alkyl.
In the case of converting, a bisarylalkyl ether of Formula 2 wherein R 1 is ##STR7## (acetoxy) to a corresponding acetoxy-substituted styrene, although the reaction can be carried out in the absence of acetic anhydride, it is preferred that acetic anhydride be fed to the reactor together with the reactant acetoxy-containing bisarylalkyl ether to prevent the hydrolysis of the acetoxy-containing substituted styrene product to a corresponding hydroxy-containing compound. For example, in the case of APMC-Ether conversion to 4-acetoxystyrene, it is preferred that acetic anhydride be fed to the reactor together with the reactant APMC-Ether to prevent the hydrolysis of the 4-acetoxystyrene product to 4-hydroxystyrene. The amount of acetic anhydride may be as high as about five (5.0) moles of acetic anhydride per one (1) mole of reactant APMC-Ether with the preferred amount being 0.05 moles of acetic anhydride per one (1) mole of reactant APMC-Ether. When the reaction is carried out in the absence of acetic anhydride, one (1) mole of APMC-Ether is converted to two (2) moles of 4-acetoxystyrene and one (1) mole of water in a reaction represented stoichiometrically as follows: ##STR8##
When the reaction is carried out in the presence of acetic anhydride the APMC-Ether reacts stoichiometrically with the acetic anhydride in accordance with the following reaction (Reaction 3): ##STR9##
If the amount of a cetic anhydride available for the reaction is less than the stoichiometric amount shown in Reaction 3, i.e., one (1) mole of acetic anhydride per one (1) mole of APMC-Ether, the APMC-Ether which is not converted by Reaction 3 is converted by Reaction 2.
In order to minimize the free radical polymerization of the substituted styrene product such as 4-acetoxystyrene or 4-methoxystyrene, it is preferred that a free radical inhibitor be used in the reaction to inhibit polymerization. Any known inhibitors such as phenothiazine, t-butyl catechol or the like that effect such quenching may be used. The use of the inhibitor, however, is not necessary for the reaction of the present invention to be carried out.
(b) Preparation of Bisarylalkyl Ethers from Arylalkanols
As discussed in the Background of the Invention section hereof, the present invention discloses a method of preparing bisarylalkyl ether from corresponding arylalkanols. The reaction is represented as follows (Reaction 4): ##STR10## wherein R 1 is ##STR11## --O--CH 3 , --O--CH 2 --CH 3 , halogen or NO 2 ; and R 2 , R3, R4 and R 5 are independently hydrogen, halogen or C 1 -C 4 alkyl. The method is preferably used for the conversion of APMC to APMC-Ether and for the conversion of MPMC to MPMC-Ether.
The reactant arylalkanol is fed as liquid to a reactor together with an acid catalyst. The reactant and the catalyst are thoroughly mixed and heated to a temperature in the range of about 80° C. to about 120° C. which is sufficiently high to initiate and complete the condensation reaction shown as Reaction 4. At lower temperatures, the reaction is very slow and, at higher temperatures, the bisarylalkyl ether product such as AMPC-Ether or MPMC-Ether tends to decompose.
In order to increase the yield of arylalkanol to bisarylalkyl ether, it is preferred that the water product of the reaction be immediately removed. Accordingly, the reaction is carried out under subatmospheric conditions in the range of about 0.1 mm Hg to about 760 mm Hg to accomplish the immediate removal of the water through vaporization. The preferred pressure is in the range of about 0.1 mm Hg to about 50 mm Hg and the most preferred pressure is in the range of about 0.1 mm Hg to about 2 mm Hg.
An organic solvent may also be used to remove the water extensively and satisfactorily by codistilling the water with the solvent. The solvent may be recirculated to the reactor for further use. Examples of such solvent include, but are not limited to toluene and 1,2,4-trimethylbenzene.
Any acid catalyst may be used to carry out the reaction. Strong acid catalysts, however, such as sulfuric acid tend to promote the formation of polymers and other undesirable byproducts. Accordingly, weak acid catalysts are preferred. Examples of such catalyst include, but are not limited to potassium bisulfate, phosphoric acid, p-toluenesulfonic acid and ammonium bisulfate. The most preferred acid catalysts are those having a dissociation constant similar to the dissociation constant of potassium bisulfate, (pKa≃2 (relative to water)).
The amount of catalyst required varies depending on the reaction conditions and the type of the catalyst. In the case of potassium bisulfate with the reaction being carried at about 100° C., the preferred amount of catalyst is about 8 to about 9 weight percent of the total charge to the reactor.
The reaction is relatively slow and the reaction time is in the range of about 0.5 hours to about 8.0 hours depending on the reaction conditions, the catalyst and other factors. In a typical reaction wherein APMC is used to produce APMC-Ether in the presence of about 9 weight percent potassium bisulfate catalyst at about 100° C. and 0.25 mm Hg, the reaction time is from about 1.0 to about 4.0 hours.
Because the reaction time is relatively slow, the reaction is preferably carried out in a batch mode. A continuous mode, however, wherein reactants and catalyst are slowly fed to the reactor and products are slowly removed therefrom may be used.
The following examples further illustrate the invention but are not to be construed as limitations on the scope of the invention contemplated herein. Examples 1-3 demonstrate the conversion of APMC-Ether to 4-acetoxystyrene. Example 4 illustrates the conversion of MPMC-Ether to 4-methoxystyrene. Examples 5-7 illustrate the conversion of APMC to APMC-Ether. Example 8 illustrates the converstion of MPMC to MPMC-Ether. All calculations of conversions, selectivities and yields are based on moles of the compounds involved.
EXAMPLE 1
A flask heated by hot oil was fitted with a chilled water overhead condenser, a thermowell with a thermocouple, an overhead stirrer and a vacuum pump. Crude APMC-Ether (20 grams) containing 78.2 weight percent APMC-Ether, 7.2 weight percent APMC and 3.9 weight percent 4-acetoxyphenylmethylcarbinol acetate (sometimes referred to herein as "APMC-Acetate") was mixed in another flask with six (6.0) grams of acetic anhydride. Phosphoric acid (0.022 grams) having a concentration of 85 weight percent that corresponds to 0.32 moles of pure phosphoric acid per 100 moles of APMC-Ether was added to said mixture. The resultant mixture was fed to the hot flask at a rate of 1.2 grams per minute. The hot oil temperature was maintained at about 220° C. to about 230° C. and the reaction mass temperature in the hot flask was maintained at about 180° C. to about 200° C. The vacuum pump maintained a vacuum in the flask at about 80 mm Hg. 4-acetoxystyrene and acetic acid were produced in the hot flask.
The vacuum conditions caused the 4-acetoxystyrene and the acetic acid products to vaporize in the flask as soon as they were formed together with unreacted acetic anhydride. The vapors were condensed in the overhead condenser and collected in an overhead receiver. The residue and the catalyst were allowed to build up in the hot flask and were discarded after the cycle was completed.
At the end of the reaction, the total amount of residue removed from the flask was 9.3 grams and the product collected in the overhead receiver was 15.6 grams. The overhead product contained 54.6 weight percent 4-acetoxystyrene. The conversion of the crude APMC-Ether was 99.6 percent with the selectivity to 4-acetoxystyrene being 51.2 percent corresponding to a 4-acetoxystyrene yield of 51.0 percent. The yield calculation was determined on the basis of two moles of 4-acetoxystyrene being obtained per one mole of APMC-Ether and one mole of 4-acetoxystyrene being obtained per mole of APMC and APMC-Acetate.
EXAMPLE 2
A flask heated by hot oil was fitted with a chilled water overhead condenser, a thermowell with a thermocouple, an overhead stirrer and a vacuum pump. Crude APMC-Ether (20.0 grams) containing 78.2 weight percent APMC-Ether, 7.2 weight percent APMC and 3.9 weight percent APMC-Acetate was mixed in another flask with acetic anhydride (6.0 grams) and p-toluenesulfonic acid (0.027 grams). The resultant mixture was fed to the hot flask at a rate of 1.2 grams per minute. The hot oil temperature was maintained at about 220° C. to about 230° C. and the reaction mass temperature in the hot flask was maintained at about 180° C. to about 20020 C. The vacuum pump maintained a vacuum in the flask at about 80 mm Hg. The vacuum conditions caused the 4-acetoxystyrene and the acetic acid products to vaporize from the flask as soon as they were formed together with unreacted acetic anhydride. The vapors were condensed in the overhead condenser and collected in an overhead receiver. The residue and the catalyst were allowed to build up in the hot flask and were discarded after the cycle was completed.
At the end of the reaction, the total amount of residue removed from the flask was 3.7 grams and the product collected in the overhead receiver was 21.4 grams. The overhead product contained 62.9 weight percent 4-acetoxystyrene. The conversion of the crude APMC-Ether was 98.0 percent with the selectivity to 4-acetoxystyrene being 82.3 percent and corresponding to a 4-acetoxystyrene yield of 80.6 percent. The yield calculation was determined as described in Example 1.
EXAMPLE 3
A flask heated by hot oil was fitted with a chilled water overhead condenser, a thermowell with a thermocouple, an overhead stirrer and a vacuum pump. Crude APMC-Ether (20.0 grams) containing 76.7 weight percent APMC-Ether, 1.5 weight percent APMC and 4.6 weight percent APMC-Acetate was mixed in another flask. Ammonium bisulfate (0.03 grams) corresponding to 0.45 moles of ammonium bisulfate per 100 moles of APMC-Ether was added to said mixture. The resultant mixture was fed to the hot flask at a rate of 1.2 grams per minute. The hot oil temperature was maintained at about 220° C. to about 230° C. and the reaction mass temperature in the hot flask was maintained at about 180° C. to about 200° C. The vacuum pump maintained a vacuum in the flask at about 80 mm Hg. The vacuum conditions caused the 4-acetoxystyrene and acetic acid products to vaporize from the hot flask as soon as they were formed together with unreacted acetic anhydride. The vapors were condensed in the overhead condenser and collected in an overhead receiver. The residue and the catalyst were allowed to build up in the hot flask and were discarded after the cycle was completed.
At the end of the reaction, the total amount of residue removed from the flask was 2.4 grams and the product collected in the overhead receiver was 23.2 grams. The overhead product contained 65.3 weight percent 4-acetoxystyrene. The conversion of the crude APMC-Ether was 97.0 percent with the selectivity to 4-acetoxystyrene being 100 percent and corresponding to a 4-acetoxystyrene yield of 97.0 percent. The yield calculation was determined as described in Example 1.
EXAMPLE 4
A flask was fitted with a chilled water overhead condenser, a thermowell with a thermocouple, a magnetic stirrer and a vacuum pump. MPMC-ether (9.6 grams, 33.6 mmoles) was mixed with methanesulfonic acid (0.0062 grams, 0.065 mmole) and the mixture was added to the flask. The flask was heated to 140° C. with a hot oil bath and a vacuum was maintained at 3 mm Hg. The reaction was complete in 20 minutes. The product 4-methoxystyrene was distilled over as a colorless liquid. Seven (7.0) grams of product were obtained corresponding to a yield of 77 percent.
EXAMPLE 5
A one liter, three-necked flask was fitted with thermowell, a heating mantle, a mechanical stirrer and a Dean-Stark trap. A chilled water condenser, fitted with a pressure equalizing dropping funnel and a vacuum port was placed on top of the trap. The flask was charged with 100.1 grams of APMC, 297.2 grams of 1,2,4-trimethylbenzene and 38.1 grams (8.8 weight percent) potassium bisulfate. The reaction was heated to reflux at 90° C. under vacuum conditions (143 mm Hg). The reaction mass was continuously stirred for good mixing. After 100 minutes, the reaction was allowed to cool and was gravity filtered. The filtrate was shaken with 10.0 grams of sodium bicarbonate and was allowed to stand for one hour. The mixture was filtered and the filtrate was concentrated on a rotary evaporator at 1.0 mm Hg. The oil was shaken with an equal weight of petroleum ether to remove residual trimethylbenzene. The product was allowed to phase separate and the petroleum ether was stripped on the rotary evaporator at 143 mm Hg. Treatment with petroleum ether was repeated and, after rotovapping, the residual oil was analyzed by gas chromatography. The yield of APMC-Ether, based on APMC, was about 51 percent.
EXAMPLE 6
A three liter three-necked flask was fitted with a thermowell, a heating mantle, a mechanical stirrer and a Dean Stark trap. A chilled water condenser leading to a bubbler was placed on top of the trap. The flask was charged with 250.4 grams of APMC, 742.4 grams of toluene and 94.7 grams (8.7 weight percent) of potassium bisulfate. The reaction was heated to reflux at 111° C. After five (5.0) hours the reaction was sampled for gas chromatography analysis. The reaction was carried out under atmospheric pressure conditions (760 mm Hg). The conversion of APMC was 79.4 percent and the selectivity to APMC-Ether based on APMC 63.7 percent corresponding to a yield of APMC-Ether based on APMC of 51 percent.
EXAMPLE 7
A 100 milliliter two-necked flask was fitted with a thermowell, a magnetic stirrer and a vacuum port. The flask was charged with 59.35 grams of APMC and 5.69 grams (8.7 weight percent) of potassium bisulfate. The reaction mass was heated on an oil bath at 100° C. under 0.250 mm Hg. After 2.0 hours, the reaction was sampled for chromatography analysis. The yield of APMC-Ether, based on APMC, was about 84 percent.
EXAMPLE 8
A 100 milliliter flask equipped with a condenser, a magnetic stirrer and a hot-oil bath was charged with 4-methoxyphenylmethylcarbinol (MPMC) (50.0 grams) and p-toluenesulfonic acid (0.066 grams). The reaction mixture was heated to 80° C. and was stirred for 16 hours. The reaction mixture was then cooled to room temperature. Then it was dissolved in ethyl acetate (250 milliliters) and was washed with water three times with 250 milliliters of water each time. The organic layer was separated from the mixture and was dried over anhydrous magnesium sulfate. Then, it was concentrated on a rotary evaporator. The product was analyzed by gas chromotography which showed it to contain MPMC-Ether (70 percent), MPMC (17 percent) and 4-methoxystyrene (10 percent). This corresponds to an MPMC conversion of 83 percent. Distillation of this mixture under reduced pressure afforded pure MPMC-Ether.
While the invention is described with respect to specific embodiments, modifications thereof can be made by one skilled in the art without departing from the spirit of the invention. The details of said embodiments are not to be construed as limitations except to the extent indicated in the following claims. | A process for preparing a substituted styrene by reacting a bisarylalkyl ether in the presence of an acid catalyst is disclosed. The process is preferably used for the preparation of 4-acetoxystyrene from 4,4'-(oxydiethylidene)bisphenol diacetate and 4-methoxystyrene from 4,4'-(oxydiethylidene)bisphenol dimethyl ether. A process for preparing a bisarylalkyl ether by reacting a corresponding arylalkanol in the presence of an acid catalyst is also disclosed. | 2 |
[0001] The invention relates to the application of specific laser treatment for the removal of electrically non-conductive surface protection layers of aircraft components so as to produce mass connection areas before establishing a connection with an electrical mass cable.
[0002] Results of the tests carried out have shown that suitable laser treatment completely removes non-conductive surface layers, such as e.g. paint and oxide layers, from aluminium surfaces without thereby damaging the base material. The precipitation state and the corrosion resistance of the aluminium base material remain unchanged, and the electrical conductivity after laser mirroring is comparable to that of a non-coated aluminium surface. With controlled suction removal of dust residues that have not been vaporised directly, workplace health and safety regulations can be met significantly better than is the case with conventionally applied brushing or grinding processes. Furthermore, negative influences on the operator and on the materials can be considerably reduced.
[0003] Below, the results are explained in the context of transverse sections, microhardness tests, corrosion tests (intercrystalline corrosion tests and salt-spray corrosion tests), REM and EDX analyses.
STATE OF THE ART/LITERATURE
[0004] Aircraft are constructed in such a way that electrostatic charges do not result in any damage to or malfunction of electrical systems or of the structure. Good electrical conductivity both of the structure and of equipment components serves to bleed off electrical charges and to establish sound electrical mass connection of the electrical system. All the electrically conductive components such as e.g. the fuselage, wings, tail unit, flaps or tabs, landing gear, and engine fairings or cowlings have to comprise mass connection areas.
[0005] In the past, electrical mass connections (mass connection areas) were produced by masking the respective aluminium surface by means of an aluminium foil prior to the application of a surface protection layer. After application of the surface protection layer, the protective foil was removed and, following cleaning of the surface, mass connection was established by means of a connecting shoe and a connecting cable. If during application of the surface protection layer non-conductive layers such as anodisation agent or paint found its way below the protective foil, these layers subsequently had to be removed by means of a fast-rotating brush or a grinding disc. These methods were time-consuming, and therefore uneconomical, and were associated with a disproportionate expenditure of money, time and energy; a factor which was also reflected in the quality, i.e. in the quantity of material that had to be removed, and in poor surface quality.
[0006] Thanks to advances in laser methods over the past few years, laser-assisted processes are becoming increasingly interesting for applications such as e.g. the removal of layer systems. It is now possible to use lasers for cleaning processes or activation processes prior to the application of paint, or to use them for the removal of paint or layers in production, service and maintenance. Depending on the absorption behaviour of the layers to be removed, or of the surface impurities, excellent surface pre-treatment and quality can be achieved. Nonetheless, it is important in such applications to avoid any negative influence on the base material.
[0007] Laser methods have the potential for use in the cleaning, activation and layer removal of aircraft components even in cases where the areas that have to be treated are larger than those that are necessary as electrical mass connection areas.
LITERATURE
[0008] 1. Schweizer, G.; Werner, L.: Industrial 2 kW TEA CO 2 laser for paint stripping of aircraft 10 th Int. Conf. on Gas Flow and Chemical Lasers (GCL 94), Friedrichshafen Germany (1994)
[0009] 2. Bianco, M. et al.: Laser stripping of paints for aircrafts: A comparison between traditional and TEA superpulsed CO 2 lasers, Surfair XI, Cannes (1996)
[0010] 3. Kelley, J. D.: Flashjet coatings removal process—transition from development to production, Surfair X I, Cannes (1996)
OBJECT OF THE INVENTION
[0011] For the purpose of clarifying the object of the invention, FIG. 1 diagrammatically shows an electrical mass connection. The object is to produce a clean, flat, electrically conductive surface so as to ensure good contact with the mass connection cable.
[0012] This object is met by a “laser mirroring” process for preparing electrical mass connection surfaces. FIG. 2 shows the result of this, namely a mass connection surface.
DESCRIPTION OF THE INVENTION
[0013] Tests have shown that with this process it is possible to remove non-conducting surface protection systems such as chromic acid anodising (CAA) layers or sulphuric acid anodising (SAA) layers, primers and topcoat paints. For comparison purposes, the ability to remove differently structured paint systems, e.g. solvent-based, water-based as well as chromate-containing and chromate-free systems, was tested.
[0014] The base materials used for the investigations were conventional aluminium alloys (e.g. Al 2024 ) as used in aircraft engineering. The alloys tested were in plated and non-plated states and also in various commonly used heat treatment states. Tests were carried out both on suitable sheet material samples and on corresponding aircraft components.
[0015] In order to experimentally determine the basic feasibility, various laser systems were used: a TEA-CO 2 and an Nd: YAG laser, both operated with pulsed laser beams. The laser processing parameters such as the average laser beam output, pulse repetition frequency, laser beam focus diameter on the component surface, scan parameters and process- and handling parameters were greatly varied in order to obtain an optimal result that was tailor-made for the aircraft components used.
[0016] FIG. 3 diagrammatically shows the requirements which an electrical mass connection has to meet. In order to obtain a suitable surface for the mass connection, the non-conductive surface protection layer around the drill hole has to be completely removed. To ensure proper removal the non-conductive layer needs to have adequate capacity to absorb the laser radiation at the selected wavelength. In contrast to this it is advantageous if the base material has a high capacity to reflect the laser radiation.
RESULTS AND DISCUSSION
[0017] FIG. 4 shows the treated surface following mechanical removal of the layer (mechanical mirroring) using a fast-rotating brush. This process not only removes the paint and the anodic oxidation but also the plating layer and the base material. By way of comparison, FIG. 5 shows the surface and the transverse sections after treatment with TEA-CO 2 and Nd: YAG (Neodymium: Yttrium Aluminium Garnet) lasers. The figure clearly shows the excellent condition of the plating layer that is present without any damage following laser treatment. Even in microscopy examinations, both types of laser result in good plane removal of the paint without any visible damage to the plating layer. However, in the case of the CO 2 laser, residues were found directly at the transition between the treated and the untreated areas, which residues presumably are the result of optical interference which can occur with the use of a mirror-guided CO 2 laser. In comparison to this, the Nd: YAG laser showed a very good transition, without any residue, to the laser-treated area. Furthermore, the Nd: YAG laser provides the option of using a fibre coupling, which opens up the system's ability to mobile applications. For this reason an Nd: YAG laser with fibre coupling was selected for further tests.
[0018] FIG. 6 shows scanning electron microscope images of the transition areas of mechanically-treated and of laser-treated components. Paint adhesion tests in the transition area did not show any impairment of paint adhesion around the area where removal had occurred. FIG. 7 shows a transverse section of a fully laser-treated mass connection area. Again, an excellent surface finish and complete removal of paint is evident. The conductive plating layer (light-coloured area) remains completely undamaged. To prove that the very thin anodic layers of chromic acid (CAA) and sulphuric acid (SAA) respectively were removed by the laser, samples were made that were only coated with these anodic oxidation layers. Here again, the excellent removal of these layers by means of the laser and by means of correspondingly set laser parameters is evident (see FIG. 8 ).
[0019] By varying the laser radiation, beam scanning, as well as the process and handling parameters, a large spectrum of various removal results is obtained. From the point of view of economy, a low laser output of 120 watt and the option of extremely fast treatment and production of mass connection areas, combined with very good surface quality, are advantageous. Irrespective of the thickness of the layer, the absorption behaviour etc., it takes approximately 1 second to produce mass connection areas approximately 15 mm 2 in size.
[0020] Laser mirroring is carried out by a pulsed laser beam that generates a specified size of the focal spot within a few nanoseconds. By way of an example, FIGS. 9 a ) b ) and c ) diagrammatically shows the variation of the tracking width and the spacing of the focal spot between the set focal spots. In addition to the tracking width, the spacing between focal spots, the number of passes, the direction of passes (horizontal and vertical) can be varied to treat layers uniformly and obtain a removal result which is optimised in relation to the components to be treated.
[0021] Microhardness testing of the laser-treated materials shows no difference to virgin materials. To this effect, hardness impressions were made from the surface to the interior of the material on transverse sections ( FIG. 10 ).
[0022] FIG. 11 shows the results of corrosion tests after a salt-spray corrosion test according to ISO 7253 lasting 168 h. While the mechanically mirrored samples showed clear signs of corrosion (both uniform corrosion and selective corrosion or pitting) due to the intact plating in the samples subjected to laser mirroring, no visible signs of corrosion were found.
[0023] Based on the sensitivity of the precipitation state in the face of thermal influences, tests were carried out to determine the sensitivity to intercrystalline corrosion. These tests did not show any increased sensitivity of the materials to intercrystalline corrosion (i.e. no noticeable change in the precipitation state). Both samples, i.e. the laser-treated sample and a bright non-coated aluminium sample, show a comparable depth of intercrystalline corrosion of approx. 150 μm. These results were further confirmed in microscopic examinations at higher resolutions ( FIG. 12 ).
[0024] EDX analyses, too, showed good removal of all surface impurities after completion of the laser mirroring process (compare FIGS. 13 a and b ).
[0025] The possibility of removing non-conductive surface layers was investigated in the context of producing electrical mass connection areas. The results of these investigations show that the production of electrical mass connection areas by means of a laser is feasible. Similar laser equipment can also be used for large-area removal of layer systems from various substrates. Similarly, plant engineering can be applied in the mobile use of an optical laser system, designed as a handheld system. Furthermore, with the use of a laser, the quantity of dust particles arising when compared to conventional brush or grinding methods is reduced, and controlled suction becomes possible. It should also be mentioned that no evidence was found of either physical or thermal damage to the components. Aspects such as surface quality and finish, productivity and environmental protection are additional beneficial factors. | Stripping is accomplished with a pulsed laser beam that targets the material and area to be stripped. The wavelength laser beam may be selected or adjusted to the absorption behavior of the material to be stripped without damaging the underlying base material. A control unit may operably adjust an optical system to guide the laser beam over the surface to be treated. a coating. This makes it possible to improve the surface stripping process. | 1 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is based on and claims priority to U.S. Provisional Patent Application No. 61/665,976 filed on Jun. 29, 2012, which is incorporated herein by reference in its entirety for all purposes.
FIELD OF THE INVENTION
[0002] The present invention relates generally to the field of well water information and devices and methods of retrieving and recording said information. More particularly, the present invention relates to devices and methods of continuously monitoring water level in a well.
BACKGROUND
[0003] Many residential homeowners rely on the use of a well to supply water to their home. Likewise, many farmers rely on the use of a well to supply water to irrigate crops or to keep animals hydrated. Private water wells are a common feature in areas where municipal or city water services are unavailable or where surface supplies are not sufficient or accessible. Water wells are commonly used to source groundwater where naturally occurring groundwater exists in spaces between rocks and/or sand. The wells themselves are bore holes either drilled or pressed into or through the ground into which casing pipes, screens, pumps and other water plumbing are installed. Groundwater seeps through openings in the casing pipe called screens. Water can be pumped via these wells, either with an above ground vacuum pump or, where the water is deeper than 30 feet, with a submersed pump that creates upward pressure to move the water to the surface.
[0004] A conventional well typically includes a borehole from the surface to a required depth to reach the ground water. A casing pipe is inserted into the borehole and grout is used to seal the space between the casing pipe and the earth. A pump (either submersed or above the ground water surface, depending on depth) is attached to the water pipe for transportation of water from the well to the point of use. The well is capped at the well head on the ground surface with a well cap. Typically, information which may include a service contractor's phone number and a date of service may be recorded on the well cap.
[0005] Water well construction (and sometimes site selection or location advisement) is done by a well driller, who takes care to design the well to meet the needs of the people who will use the water. The well driller, in the process of planning and drilling, will determine where there is ample groundwater, and will size the length and diameter of the well and casing pipe and the capacity and location of the pump accordingly. The driller will take special care to know the top elevation and the productivity of the groundwater table. Elevation is often found by measuring down from the well head (top of the well) to the water surface. Productivity of the well is inferred by measuring the elevation of the water and time it takes to return to a resting level after a pumping event has removed water to the well, a process called recovery. Together with elevation and productivity, the final pump selection is made and construction can be completed.
[0006] This water information is necessary to determine the well location in relation to the location of a building, a field of crops, or a neighborhood. At also informs the semi-permanent placement of the pump in the well. If the pump is placed too high in the well, it risks running dry and breaking prematurely. If the pump is placed too low in the well, then the owner will pay extra for the energy required to pump water an unnecessary distance. This information is typically only gathered once, however, at the time of construction. The lack of subsequent information gathering sometimes leads to new issues with the well or the pump that could have been prevented if only the well driller or homeowner had such information.
[0007] A borehole well may be considered to be healthy as long as sufficient ground water seeps through a screen section of the casing pipe into the column to allow for water to be pumped from the well. This state of balanced supply and demand is called a “safe yield”. As is known to those skilled in the art, a borehole well, the water system, and sometimes the pump equipment will not tolerate long periods of an unsafe yield. For example, a submersible pump must be kept submerged under water for proper operation. Failure to keep the pump submerged causes the pump to overheat and fail. Failure of a pump requires the well to be opened by a technician and the pump must be physically retrieved and repaired or replaced. Thus, a previously recognized problem has been that it is difficult to know the water level in the well and how close the pump may be to reaching the unsafe yield point. In a worst-case example, a borehole well will be pumped dry, the pump will fail, and the water table will have been permanently lowered in the area, effectively rendering the well useless. Needless to say, it is desirable to know about water levels in the casing pipe.
[0008] Existing methods of determining water table levels include mounting a sensor under the water in the well with wires communicating to the well head, pressure sensors built into the pump, and opening the well head to physically inspect the well with a plumb bob. Various other methods are known which all necessitate physically opening the well head to inspect the water table level.
[0009] One unsatisfactory previously recognized approach, in an attempt to solve the problem referred to herein, involves use of an airline to compress air in the casing pipe in an attempt to raise water to the surface, indicating the level. Another unsatisfactory method is to use a simple sonar instrument, not unlike a consumer grade fish finder, to find water level in the well. Certain environmental factors, like temperature, casing pipe material, well straightness, depth, and obstructions can render these devices inaccurate, so they are not as popular as mechanical tapes. In yet another previously recognized approach, contractors often carry a well level device that includes a moisture sensor at the end of a measuring tape that is temporarily inserted into a well and which makes a sound when it touches water, indicating the distance to the water. This technique is known to be reliable and inexpensive, but like the other previously described techniques, it is only designed for the well contractor's use to take one reading at a time, and to not log data or spot trends without repeat visits and manual collection, which is impractical and rarely happens.
[0010] A disadvantage of these previously recognized approaches is that due to water levels in the ground being dynamic, the data acquired is quickly dated and inaccurate once the technician completes the test. There is virtually no ongoing monitoring of safe yields of the well's water level. Additionally, users do not know if they are using more water than they should until it is too late. One common indication of overuse is that the pump fails due to dry run, indicated by a lack of running water from faucets or to toilets or appliances. Failures caused by overuse can be very expensive to repair, ranging in price from thousands of dollars to replace a pump or clear a well, to tens of thousands of dollars to dig a deeper well. In some cases, systemic overuse by many consumers in a region can even tax the ground water to the point of concentrating pollution or even running everyone's well dry. Homes in areas where there is severe water risk can quickly lose value.
[0011] On higher capacity, higher criticality water wells owned by water municipalities and some high-use agriculture businesses, water elevation information is collected continuously with pressure sensors mounted in the well under the water level connected to data logging equipment at the surface. Data provided by these devices is vital for controlling flow and therefore system performance. So a pressure sensor is part of a larger SCADA (Supervisory Control and Data Acquisition) system that keeps water flowing continuously. But these devices are expensive to install and maintain and may be part of a larger control network and scheme so they are not suitable or economically viable for homeowner or intermittent farm or business use.
[0012] When commissioning or repairing a well, a well driller may also perform a “pump test” to determine the ideal location for the pump. Using a sacrificial test pump, the well driller tests the pumping level and drawdown of the well, that is, the changed water elevation while the pump is running at its target capacity. The process involves installing the sacrificial test pump in the well deep under the static water level and running it at a flow rate equal to the anticipated peak demand of the well. When water is pumped to the surface, the water level in the well drops dramatically at first, and then the rate of decline begins to decrease until the pressure created by the water table equals the pressure created by the pump and groundwater runs into the well at the same rate that the well pumps water to the surface. The level of the water at which the pressure created by the water table equals the pressure created by the pump is the ideal vertical position of a pump in the column. Of course, the ideal vertical position of the pump at the time of commission or repairing may not be the ideal vertical position in a day, a month, or even years after the pump test is performed. However, because performing pump tests as described are costly and time intensive, they are not performed until repair is needed.
[0013] Finally, whereas in the recent past, sparse rural population, stable weather and slower agricultural and economic development did not threaten the natural recharge capabilities of most groundwater sources, today, population, overconsumption and climate changes have begun to tax the groundwater resource measurably. Hydro-geologists call this “unsafe yield.” So water wells constructed a few years ago based on a groundwater elevation measured at the time are not able to produce as designed, and often fail prematurely.
[0014] As discussed, monitoring groundwater elevation continuously in residential and agricultural wells is becoming more important, but existing monitoring solutions are not effective. Measuring with a tape continuously is impractical and will always only be for one time use (a snapshot taken at one moment). Measuring with inaccurate sensors does not yield usable information. Outfitting intermittent use wells with pressure sensors and control networks is not cost effective or even necessary. Smart operations methods and an understanding of trends are needed as conditions change.
[0015] What is needed therefore is a device that allows monitoring of the well's water level on a continual basis. What is also needed is a way to monitor the well's water level preferably without repeated removal of the well head. Further, what is needed is a way to retrofit existing wells with a device that continuously monitors the well's water level preferably without repeated removal of the well head. Heretofore, these requirements have not been fully met without incurring various disadvantages.
SUMMARY
[0016] The present invention relates to a well head water level sensing system that allows continuous monitoring of water level in a residential well. The well head water level sensing system includes a signal generator, a triggering circuit, a tunable listening device, environmental (e.g., temperature and/or humidity) sensors for calibration, a clock, a secondary listening sensor for timed or provoked events, a data logger, and power and communication circuits. The well head water level sensing system relies on the sonar effect and the inherent resonant frequency of a tube to estimate the distance from the signal generator to the water level in the well.
[0017] An alternative embodiment of the invention is a water level sensing device having a simple, solar-powered sensor and communication module that gathers information about the level of water in a borehole-style water well and sends the information to a database that a homeowner can access via a computer, handheld device, or smart phone. The water level sensor tracks the level of water in the well, how it changes over time, the pace of recharge (water replenishment from the groundwater source), and can be programmed to send alerts to interested parties when user-predetermined thresholds are reached. The water level sensor and a website enable a well owner to use water mindfully within safe yield, and can help prevent costly water or well shortages, equipment failures, or other emergencies.
[0018] The water level sensor can preferably be attached to the exposed well head by a handy homeowner using a few common tools. In some applications, only a replaceable battery is required to power the sensor. And in others, power can be harvested from existing power wiring, without connections, using a current transducer and a power monitoring circuit. And in others, a photovoltaic cell affixed to the sensor or, optionally, on a flexible wand to raise the solar cell, charges and recharges a battery which powers all functions. A sensor is installed just inside the existing well cap, through vent holes that may be in the existing well cap, or within a new, replacement well. The data it collects is compiled in memory and sent to a database, where it is stored and analyzed.
[0019] It will be understood by those skilled in the art that one or more aspects of this invention can meet certain objectives, while one or more other aspects can lead to certain other objectives. Other objects, features, benefits and advantages of the present invention will be apparent in this summary and descriptions of the disclosed embodiment, and will be readily apparent to those skilled in the art. Such objects, features, benefits and advantages will be apparent from the above as taken in conjunction with the accompanying figures and all reasonable inferences to be drawn therefrom.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] FIG. 1 is a schematic view of one embodiment of a water level sensing system in accordance with the invention;
[0021] FIG. 2 is a section view of one embodiment of a water level sensing device in accordance with the invention;
[0022] FIG. 3 is a section view of another embodiment of a water level sensing device in accordance with the invention;
[0023] FIG. 4 is a section view of another embodiment of a water level sensing device in accordance with the invention;
[0024] FIG. 5 is a flowchart of the operation of one embodiment of a water level sensing system in accordance with the invention;
[0025] FIG. 6 is a perspective view of another embodiment of a water level sensing device in accordance with the invention; and
[0026] FIG. 7 is a perspective view of another embodiment of a water level sensing device in accordance with the invention.
DETAILED DESCRIPTION
[0027] Referring first to FIG. 1 , a water well includes a casing pipe 40 inserted into a borehole in the earth. The borehole is drilled deep enough to encounter ground water 65 . A pump 60 is lowered into the casing pipe 40 and is submerged under water 65 . The casing pipe 40 includes a screen 49 for screening out sediments through which water 65 seeps. An integrated supply water pipe 50 as shown in FIGS. 2-4 , supplies water from the pump 60 to any location, which may include a home.
[0028] Turning now to FIG. 2 , a well head water level sensor 100 for a well in a region where there is a frost line is shown. The well head water level sensor 100 has cap-integrated sensors 102 . In the embodiment shown, the standard well cap is removed and a new well cap 104 , including the aforementioned sensors and other components is installed in its place. Electronics 106 are housed inside the well and under the well cap 104 , apart from antenna 108 . A data port and access to a battery for replacement are provided as well. A solar cell and/or other power supplies could also be used. Signals to the aforementioned components pass via wires 110 that lead through a sealed hole in the cap.
[0029] Turning now to FIG. 3 , a well head water level sensor 200 for a well where the existing well cap 45 cannot be replaced is shown. In this embodiment, the well head water level sensor 200 is attached to the underside of the existing well cap 45 using any suitable means, e.g. screws, adhesive, etc. External electronics 206 are housed outside of the casing pipe 40 in a rugged box 208 attached to the pipe. Communication between internal sensors 210 and external electronics 206 is made via flat, durable ribbon cable 212 that passes across gaskets 214 without breaking the mechanical seals between the casing pipe 40 and the cap 45 . Other communication means between the internal sensors 210 and the external electronics 206 may also be used, e.g. wireless communication.
[0030] Referring to FIG. 4 , a well head water level sensor 300 for a well in a region where there is no risk of freezing is shown. The well head water level sensor 300 utilizes a vent hole 302 common in well caps found in these regions, and will act as a seal for the hole. As shown, electronics 304 are housed inside the casing pipe 40 , but may also be attached above the well cap outside the well. The vent hole 302 acts as an access port and conduit for signal and power wires 306 and mounting hardware.
[0031] A well head water level sensor for a well and its related components may alternatively be placed on the outside of the casing pipe 40 or on top of the well cap 45 .
[0032] In this configuration, sensors may be attached to the existing well hardware and is configured to be able to gather information through that hardware.
[0033] As shown in the flowchart of FIG. 5 , the embodiments shown in FIGS. 2-4 overcome the drawback of conventional acoustic water level sensors that make a sound and listen for the echo and time the period to calculate distance, by providing an adaptable sensor that is reliably accurate across a wide range of well configurations. The embodiments shown in FIGS. 2-4 all include the same components, but vary in how the components are packaged and placed on the well. Each well head water level sensor 100 , 200 , 300 includes a micro-processor controlled signal generator 102 , a triggering circuit 104 , a tunable listening device 106 , environmental sensors 108 that measure temperature and/or humidity and help calibrate the water level sensor, a clock, a secondary listening sensor for timed or provoked events, a memory for logging data, and power and communication circuits.
[0034] The well head water level sensor 100 , 200 , 300 relies on two physical phenomena to gather information: 1.) the sonar effect to estimate distances to surfaces, and 2.) the inherent resonant frequency of a tube to help distinguish between obstructions, friction, bends and curves, and the actual water surface. This phenomenon can be observed in any wind instrument or pipe organ: a tube of a given length will resonate at a given frequency. By combining these two functions in the well head water level sensor 100 , 200 , 300 , it can be made from common, albeit modern, and therefore capable and small components, and be placed at the top of the well, rather than in the water, and be highly accurate across a wide range of well sizes, shapes and configurations.
[0035] In the embodiments shown, the signal generator 102 generates a digitized low amplitude single pulse sine-wave sound (frequency is not a major factor in operation, but is determined by the limits of the signal generator, amplitude is determined by balancing well size and power consumption) and then listening. Many echo responses are heard, some larger and longer than others. Since wells differ, it is common for an echo created by an obstruction to be misinterpreted as water elevation, when it is not. For that reason, practitioners distrust basic sonar tools at worst, or consider them to be useful only for a low-resolution estimate. To improve the accuracy of the reading, the well head water level sensor 100 , 200 , 300 proceeds to a second step: reflections are analyzed for time, and the signal generator 102 responds by sending a new batch of single pulses, this time, coordinated at period identified by the largest reflection, which is assumed to be the natural resonant frequency of the distance of the tube from generator to the most complete obstruction, which in this case is the water surface.
[0036] If the timing is, in fact, the resonant frequency of the pipe distance to the water surface, the heard responses will begin to gain in amplitude. This occurs because the source pulse and the return echo are in perfect phase and reinforces the sound pressure level at the receiver. If this gain in amplitude phenomena is not observed, the signal generator 102 will alter its pulse timing to the next largest response, and so on. Once resonance is identified, it is confirmed by tuning the timing of additional pulses. As a confirmation to prevent a false positive occurring from some geometric feature of the well (or miscellaneous partial obstructions within the well), the source pulse timing is shifted to lag or lead 180 degrees in time relative to the source sound wave frequency. If the prior assumed resonance pulse timing that caused a gain in amplitude is the actual echo from the water's surface, the amplitude of pulses at the receiver will decrease significantly due to the source pulse and the echo canceling each other and thereby reducing the sound pressure at the receiver. The lowest pulse timing that causes these to conditions to occur, can only be the true resonant frequency of the well.
[0037] Because the well head water level sensor 100 , 200 , 300 performs a series of tests to find both sound reflections and the well's resonant frequency, the sensor can be accurate in and adapt to nearly any drilled well environment.
[0038] The well head water level sensor 100 , 200 , 300 also includes an environmental sensor 108 because the speed of sound in the air is affected by the air temperature and relative humidity. The environmental sensor 108 includes a temperature reading device 110 , positioned at a location accounting for variations in surface and deep depth temperatures, and providing information to adjust final water depth calculations.
[0039] As a final check of data integrity after initial power up, readings are compared before and after a pumping event signaled by the triggering circuit 104 . If no change in time response data is observed, the device will assume that it is not seeing the variable water surface, but a permanent obstruction, and will recalibrate to the next most likely response signal. Simple math is then used to calculate water elevation from sensed data, calibrated with readings from the environmental sensor 108 , and a log of time-stamped readings is assembled and made ready to be shared.
[0040] To enable semi-continuous monitoring of a water well, it is necessary to position the sensors 102 , 108 in such a way that they can see into the well while not needing to open the well or expose the water to open air or contamination and to leave them there, to operate over months and years. Additionally, its work must be done and information collected and accessed or transmitted at the surface without special tools or connections. The embodiments shown in FIGS. 2-4 are designed to either replace an existing cap or utilize existing vents and access points without leaking or altering normal operation of the well.
[0041] FIG. 6 shows another embodiment of a well head water level sensor 6 in accordance with the invention. A well head water level sensor 6 is attached to the external side of the casing pipe 40 with the use of clamps 30 . Of course, well head water level sensor 6 may be attached to the casing pipe 40 by any suitable means. In the embodiment shown, well head water level sensor 6 may be retrofitted on an existing well without removal of the well head 45 and without drilling into the casing pipe 40 or the ground. Well head water level sensor 6 contacts the casing pipe 40 on an external side of the casing pipe 40 and is held in place with the compressive force of the clamps 30 . In an alternative configuration, well head water level sensor 6 may be attached to the top of the well cap 45 , rather than being mounted to the side of the well pipe 40 . Well head water level sensor 6 transmits a sensing signal that may be in the form of an acoustic signal into the body of the casing pipe 40 . Well head water level sensor 6 is waterproof and impervious to high humidity levels. The solid construction renders well head water level sensor 6 tamper and vermin-resistant.
[0042] A transmission device within well head water level sensor 6 transmits the computed ground water level to a wireless network which may be a cellular network, a satellite network, or any other suitable wireless network. The wireless network may then relay the computed ground water level to a globally accessible network 70 which may include the Internet, the World Wide Web, or any other known globally accessible network. A handheld device which may include a smart phone, a tablet computer, a pager, or any computer that has access to the globally-accessible network 70 may then download 80 the ground water level information from the water well and display the ground water level information in any form, including a graph. Well head water level sensor 6 may be programmed to periodically transmit a data set which may include the ground water level to the wireless network.
[0043] Well head water level sensor 6 is shown with a whip module 14 that includes a shaft 20 , a solar panel 25 , and a base plate 15 . As shown, a light emitting diode 35 indicates whether well head water level sensor 6 is functioning properly. The light emitting diode 35 may also be programmed to flash or change color to indicate warnings or to indicate any programmable message.
[0044] Referring to FIG. 7 , another alternative embodiment of a well head water level sensor 7 is shown. Well head water level sensor 7 functions exactly as previously described well head water level sensor 6 except that a solar panel 16 replaces the whip module 14 and is attached directly to the front cap 5 . Well head water level sensor 7 may be beneficial to use when the well head 45 has an unobstructed view of the sun at all times of the day. In certain applications well head water level sensor 6 may more advantageously generate electricity for the well head water level sensor 6 through use of the whip module 14 where there is tall grass, shrubs, trees, or snow that may potentially block sunlight from reaching solar panel 16 . The shaft 20 of the whip module 14 may also be constructed of any suitable length that allows the remote solar panel 25 to have an unobstructed view of sunlight. FIG. 6 discloses both the solar panel 16 and the whip module 14 , which as mentioned above, are interchangeable.
[0045] Turning back to FIG. 1 , a well head water level sensor system is shown. As described previously, the well includes a well head 45 , a casing pipe 40 inserted in a bore that is drilled through the ground 55 , and a well pump 60 that is submerged in the ground water 65 . A screen 49 filters out sediment and allows the ground water 65 to seep through to the well pump 60 . The well pump 60 pumps water from the well to the surface for use in a home 85 . The well head water level sensor system transmits a signal 75 indicating ground water level to the globally accessible network 70 . While FIG. 1 shows the globally accessible network in the form of a satellite, the network may also be a cellular tower, the Internet, a WiFi connection or any suitable network.
[0046] The well head water level sensor 100 , 200 , 300 , 6 , 7 is designed to be installed and forgotten. The photovoltaic cell is large enough to provide power for full operation during the day. The battery provides enough power for night time operation, and for extended periods of cloud cover. In the embodiments shown, the battery life is approximately 5 years, when used in a well with a depth of approximately 100 feet and approximating other power consumption variables. Of course, other batteries or power supplies may be used to accommodate wells of different depths or any other reason without departing from the invention. The housing is waterproof, tamper-proof, vermin-proof, and durable enough to withstand small contact with branches, weeds, or a passing lawn mower. An optional solar wand may also be used to extend the height of the solar photovoltaic cells, accounting for deep snow, or bush and plant growth.
[0047] Although the invention has been herein described in what is perceived to be the most practical and preferred embodiments, it is to be understood that the invention is not intended to be limited to the specific embodiments set forth above. Rather, it is recognized that modifications may be made by one of skill in the art of the invention without departing from the spirit or intent of the invention and, therefore, the invention is to be taken as including all reasonable equivalents to the subject matter of the appended claims and the description of the invention herein. | A module gathers information about the level of water in a water well and sends the information to a database. A sensor tracks the level of water in the well, how it changes over time, and the pace of recharge including the rate of water replenishment from the groundwater source. The system can be programmed to send alerts to interested parties when certain thresholds are reached. | 6 |
TECHNICAL FIELD
[0001] This disclosure relates generally to heating, ventilation and air conditioning (HVAC) systems, and more particularly to a modular assembly design for a HVAC system on a work machine.
BACKGROUND
[0002] In existing underground mining machines, such as load-haul-dump machines, the heating, ventilation and air conditioning (“HVAC”) components are positioned in various locations around the machine. This can make maintenance of a HVAC system difficult and time consuming.
[0003] Exterior of the cab, a compressor charges a refrigerant fluid to the optimum pressure for cooling efficiency and circulates it around the system. A condenser and fan package is located near the engine radiators. The condenser and fan cools the refrigerant at high pressure, so that at discharge the refrigerant potential thermal energy is well below that of the ambient environment.
[0004] Within the cab of the machine, an evaporator core and blower unit are co-located in a conditioner box, typically attached to the ceiling of the cab. The evaporator core cools air that is pushed through by the blower. Assisting the evaporator core is an expansion valve, which regulates the refrigerant flow within the evaporator. Allowing expansion of the fluid within the evaporator increases the potential cooling capacity, as the expansion further cools the fluid.
[0005] An optional heater core utilises warm engine coolant to heat the same air stream, if the operator is cold. A pressuriser is mounted on the cab outer wall and provides fresh air at a higher-than-ambient pressure to the cab. This ensures that any air leaks result in an outward flow from the cab to the environment.
[0006] The mounting of various components within the cab encroaches on the limited space available for the operator. Having the conditioner box located near the head of the operator can result in possible head injuries and also elevated noise levels. It also makes direction of the air difficult to control, particularly for demisting requirements.
[0007] The spacing out of various components can result in efficiency losses and poor control of the airflow, decreasing performance. It also makes servicing difficult, as mountings and couplings must be in easy-to-reach locations, and can prove time consuming to troubleshoot.
[0008] Whilst there have been a number of HVAC system designs that co-locate more of the components together, these are typically designed for above ground machines. However, underground machines have a further limitation on space due to the restricted width and ceiling height of underground tunnels. As the tunnels do not allow for turning of a vehicle, underground load-haul-dump machines run both backwards and forwards along the tunnel. Load-haul-dump machines are long and narrow and have a relatively low cab, with a driver typically sitting transverse to the direction of travel. The machine is articulated in its centre to provide steering capacity. All of these factors result in poor operator visibility. Therefore, the location of external components on a machine is critical to ensuring sufficient visibility is provided for the operator.
[0009] The present disclosure is directed to one or more of the problems identified above.
SUMMARY
[0010] According to a first aspect of the invention there is provided a heating, ventilation, and air conditioning (HVAC) module, for a HVAC system, mountable to a work machine, the HVAC module comprising:
a housing having at least one air outlet and at least one air inlet communicable with ducting on the work machine for conveying air into and out of the operator cab of the work machine; a mounting assembly for pivotably attaching the housing to the work machine, the housing being moveable between an operating position where the outlet and inlet are in contact with a ducting interface on the work machine, and a maintenance position, where the housing is pivoted upwards to disconnect from the ducting interface of the work machine to allow access to underlying components of the work machine.
[0013] The ducting on the work machine can include a receiver box located on the top deck adjacent the location of the HVAC module. The receiver box preferably includes two channels, an inlet channel and an outlet channel. Connected to the receiver box in fluid communication with the inlet and outlet channels are inlet and outlet ducts respectively. The inlet and outlet ducts may each be comprised of a fixed duct section connected at one end to the operator cab, and a flexible duct section connecting the fixed duct section to the receiver box.
[0014] The fixed duct sections and/or receiver box can be made from sheet steel and have a boxed construction, to ensure adequate strength and robustness. The flexible duct section can be made from rubber hump hose, which typically is robust, yet assists in sealing while allowing axial misalignment.
[0015] The receiver box can be shaped to have a generally rectangular footprint. The inlet channel and outlet channel are preferably aligned one above the other, preferably both running in a generally horizontal direction. The upper channel of the inlet and outlet channels can have a shorter distance to the lower channel; this can result in the upper surface being stepped. In such an embodiment, two upper surface sections are provided having a generally flat surface with an upwardly orientated opening. The upwardly orientated openings may include a honeycomb plate with plurality of hexagonal apertures. The upwardly orientated openings form the ducting interface for the HVAC module.
[0016] The housing may comprise a lower box and an upper lid. The lid may be clamped to the lower box in use and may be pivotally connected to the lower box. The lower box and upper lid can be made from sheet metal.
[0017] The air inlet and/or outlet of the housing may include a hood to create a channel to an opening. The opening is preferably orientated to be downward facing in the operating position. The inlet opening and the outlet opening are preferably located on the same side of the housing; this may be on the side opposite the pivot hinge connection. Surrounding the openings can be a seal, which may compress under pressure.
[0018] In the operating position, the downward facing openings of the HVAC module abut against the upwardly orientated openings of the receiver box, with their respective surfaces aligned. The interface between the respective openings is sealed by the seal located about the downward facing openings, in order to protect the seal from damage while in the service position. However, it will be appreciated that the seal may be located about the upwardly orientated openings. In the operation position, the housing may be clamped to the receiver box ensuring the seal is maintained. When moving the housing into the maintenance position, the housing may be unclamped and lifted away from the receiver box disconnecting the ducting interface.
[0019] The pivotal mounting assembly may include at least one, preferably two, pivot hinges located on one side of the housing. The pivot hinge preferably connecting the housing to the top deck of the work machine. Advantageously, the pivot hinge is a releasable hinge.
[0020] The pivotal mounting assembly may also include at least one lifting linkage on one of more of the sides of the housing perpendicular to the side of the housing the pivot hinge connection is located on. The lifting linkage may be a gas strut. The lifting linkage is configured to assist in raising the housing about the pivot hinges, so that the service technician needs to apply a comfortable load, and so that the articulation angle is limited. The lifting linkage can be releasably connected to the housing.
[0021] On the side of the housing opposite the pivot hinge connection there may be latching elements to secure the housing in the operating position.
[0022] The housing may be mounted to at least partially sit within a recess formed in the top deck of the work machine.
[0023] Advantageously, the HVAC module is a unitary assembly that is removable from the work machine and replaceable.
[0024] The HVAC module may include at least an operational component region, a condenser region and a conditioning region. The operational component region preferably includes at least a motor and a compressor, the motor operable to drive the compressor. The motor is preferably a hydraulic motor that draws hydraulic fluid from a hydraulic supply external to the HVAC module, advantageously regulated by a manifold.
[0025] The condenser region preferably includes a condenser and at least one fan, the fan(s) being operable to draw air from the ambient environment external of the housing.
[0026] The conditioning region preferably includes the at least one air inlet and at least one air outlet, evaporator and heater cores and a blower.
[0027] The evaporator core is preferably in fluid communication with the compressor and condenser to convey refrigerant. A refrigerant flow path is preferably created from the compressor to the condenser to the evaporator core and back to the compressor. Advantageously between the compressor and the condenser there is provided a high pressure charge port. There may also be a pressure sensor. There may be associated with the evaporator a thermal expansion valve. Between the condenser and the thermal expansion valve there is preferably a receiver drier. Running back to the compressor from the evaporator, the refrigerant preferably passes via a pressure sensor and a low pressure charge port.
[0028] The conditioning region may also include an additional inlet for drawing in ambient air from the surrounding environment. A conditioned air flow path is typically created by drawing ambient air through the additional inlet from the external environment into the conditioning region of the housing. The ambient air passes via at least one filter to the evaporator. A pressurizer and/or a temperature sensor may also be located in the path before the ambient air passes through the evaporator. From the evaporator the air may pass via a temperature sensor or freeze-point probe and may then pass via a heater core to a blower. The blower forces the conditioned air through the air outlet to the ducting into the operator cab. Air is also drawn from the operator cab through the air inlet and recycled back through the conditioned air flow path by passing via a filter to the evaporator mixing with the ambient air to continue on the conditioned air flow path.
[0029] Hot coolant for the heater core is preferably drawn from the engine cooling system of the work machine.
[0030] An electronic control module (ECM) may be configured to control all aspects of the HVAC system, for example including the hydraulic components and the electrical functions, and to control the temperature of the airstream reaching the operator cab.
[0031] According to a second aspect of the invention, there is provided a heating, ventilation, and air conditioning (HVAC) system for a work machine, the HVAC system comprising:
a HVAC module mountable to a work machine, the HVAC module comprising:
a housing having at least one air outlet and at least one air inlet communicable with ducting on the work machine for conveying air into and out of the operator cab of the work machine, the outlet and inlet having openings that are downwardly orientated; a mounting assembly for pivotably attaching the housing to the work machine; and
a receiver box mountable to the work machine adjacent the housing, the receiver box being connectable to ducting on the work machine and including at least one inlet opening and one outlet opening, both being upwardly orientated;
[0036] wherein the module is moveable between an operating position where the downwardly orientated outlet and inlet on the housing are in contact with the upwardly orientated inlet and outlet on the work machine, respectively, and a maintenance position, where the housing is pivoted upwards to disconnect the ducting interface to allow access to underlying components of the work machine.
[0037] As used herein, the term “comprises” (and grammatical variants thereof) is used inclusively and does not exclude the existence of additional features, elements or steps.
BRIEF DESCRIPTION OF THE DRAWINGS
[0038] The present invention will now be described, by way of example only, with reference to the accompanying drawings, in which:
[0039] FIG. 1 is perspective view of an example work machine, a load-haul-dump machine in this case, with a HVAC module according to an embodiment of the present invention installed on its top deck;
[0040] FIG. 2 is a close up view of the HVAC module shown of FIG. 1 ;
[0041] FIG. 3 is a perspective view of the HVAC module in a maintenance position;
[0042] FIG. 4 is a perspective view of the HVAC module and associated ducting and cables in a partially open position;
[0043] FIG. 4A is a perspective front view of the HVAC module;
[0044] FIG. 5 is a left view of the HVAC module and associated ducting and cables of FIG. 4 in a closed position;
[0045] FIG. 6 is a rear view of the HVAC module and associated ducting and cables of FIG. 5 ;
[0046] FIG. 7 is a cross-sectional left view through lines A-A in FIG. 6 ;
[0047] FIG. 7A is a close up view of the area circled B in FIG. 7 ;
[0048] FIG. 8 is a top view of the HVAC module with the lid removed; and
[0049] FIG. 9 is a boundary diagram of the HVAC module according to one embodiment.
DETAILED DESCRIPTION
[0050] Referring to FIG. 1 , a work machine in the form of a load-haul-dump machine 2 is shown. A load-haul-dump machine is used in underground mines and runs back and forth to scoop rubble and transport and dump it onto a conveyer. Due to the restricted height and width of underground mine tunnels, load-haul-dump machines have a narrow, long, low profile. The body 4 is centrally articulated about a flexible joint 6 dividing the body into a first body portion 8 and a second body portion 10 . Each body portion includes two opposing wheels 12 .
[0051] The first body portion 8 has a bucket 18 for scooping and hauling rubble from within the tunnel. The second body portion 10 includes an engine, and hydraulic and electrical systems (not shown). The second body portion 10 has an operator cab 20 that projects above a top deck 14 . The operator cab 20 is enclosed, with the operator seated sideways to provide adequate visibility when the machine is moving in either direction. The operator cab includes an operator control station (not shown) of the type that controls a heating, ventilation and cooling (HVAC) system.
[0052] Located generally on the top deck 14 is a HVAC module 22 . Providing fluid communication between the operator cab 20 and the HVAC module 22 is outlet ducting 36 to convey air out of the HVAC module 22 into the operator cab. Inlet ducting 34 conveys recirculated air out of the operator cab 20 back to the HVAC module 22 . This keeps the environment comfortable for the operator. Details of the ducting will be described further below.
[0053] FIG. 2 shows a close-up view of the HVAC module 22 shown in FIG. 1 . The HVAC module 22 includes a housing comprised of a lower box 24 and an upper lid 26 . The lower box 24 and upper lid 26 would typically be made from sheet steel. The lid has an array of vents 30 located towards a corner of the lid (to be discussed further below). The upper lid 26 is illustrated as being clamped to the lower box 24 with lid clamps 28 . The lid clamps 28 can be released so that the lid can be lifted upwards off the lower box 24 . However, it will be appreciated that hinges may also be provided in addition to clamps, such that the lid may be pivotally joined to one side of the lower box. The lid 26 could then be pivoted open and closed, and clamped in the closed position. A gas strut could be provided within the lower box to assist with lifting of the lid.
[0054] According to the embodiment illustrated, the lower box 24 has a longer side of approx. 874 mm, a shorter side of approx. 790 mm and a height of approx. 350 mm, therefore having a generally rectangular shape. The HVAC module is recessed into the top deck 14 to reduce the impact on the operator's visibility in that direction compared to if it were positioned directly on top of the deck 14 . The lower box 24 is illustrated as being recessed into the top deck 14 by approx. 154 mm. The recess is indicated by reference numeral 16 in FIG. 3 . This results in approx. 196 mm of the lower box 24 projecting above the top deck 14 .
[0055] The HVAC module 22 is preferably located directly above the torque converter package (not shown). As the torque converter package is typically serviced daily, the HVAC module 22 is pivotally mounted to the top deck via pivot hinges 32 . To allow seating in the recess 16 , the pivot hinges 32 are located part way down the side wall of the lower box. The HVAC module 22 is pivotable between an operating position, as shown in FIG. 2 , and a maintenance position, as shown in FIG. 3 . In the maintenance position, access can be gained to the recess 16 and therefore the torque converter package and other components located underneath for maintenance purposes.
[0056] Enabling the movement between the operating position and the maintenance position is a lifting linkage in the form of a gas strut 48 . The gas strut is connected to one side of the lower box 24 and extends down below the top deck to connect to the chassis. It will be appreciated that whilst only one gas strut is illustrated, another gas strut may be provided on the other side of the lower box. A handle 62 is provided on the lower box to assist in movement of the HVAC module by an operator.
[0057] As can be seen in FIG. 3 , there are a number of hydraulic hoses 64 connected to the underside of the HVAC module 22 . These hydraulic hoses 64 connect at their other end to the working machine. The hydraulic hoses 64 are provided with sufficient length to be able to be lifted into the maintenance position. The hoses 64 are held in place against the underside of the HVAC module 22 by platework 66 . This allows the hoses 64 to bend as the HVAC module is lowered. Additional hoses 67 are positioned at the bottom of the module to allow condensate from within the module to drip into and then purge from the box 24 . These additional hoses 67 may contain a one-way valve. An array of vents 70 can also be seen in FIG. 3 , positioned towards a corner of the base (to be discussed further below).
[0058] Also located on the bottom surface of the lower box 24 are electrical cables 68 . The electrical cables 68 run along the underside of the box 24 and are provided with sufficient length to create a loop 69 to allow flexure when the module is elevated to the maintenance position.
[0059] An air inlet opening 50 and an air outlet opening 52 are generally adjacent one another on the HVAC module 22 . Referring to FIG. 4 , it can be seen that inlet opening 50 is created by a hood 51 that projects above the planar top surface of the lid 26 . The hood 51 creates a channel from the opening 50 to an inlet into the housing. The outlet opening 52 is also created by a hood 53 that projects from the side of the lower box. The hood 53 creates a channel that leads into an outlet in the side wall of the lower box 24 . The hoods 51 , 53 are formed to orientate the openings 50 , 52 downwards, when in the operating position.
[0060] Running between the operator cab 20 and the HVAC module is the inlet ducting 34 and the outlet ducting 36 . The inlet ducting 34 includes an inlet fixed duct section 40 . One end 39 of the inlet fixed duct section 40 connects to an upper region of the wall of the operator cab 20 . The other end of the inlet fixed duct section 40 connects to an inlet flexible duct section 42 . The connection makes an elbow in the flow path (see FIG. 3 ). The inlet flexible duct section 42 then connects to a receiver box 38 mounted on the top deck 14 adjacent the recess 16 .
[0061] Similarly, the outlet ducting 36 includes an outlet fixed duct section 44 . One end 43 of the outlet fixed duct section 44 connects to a lower region of the wall of the operator cab 20 . The other end of the outlet fixed duct section 44 connects to an outlet flexible duct section 46 . Similarly, this connection can make an elbow in the flow path. The outlet flexible duct section 46 then connects to the receiver box 38 .
[0062] The receiver box 38 has a generally rectangular footprint and includes two internal flow paths. The two flow paths are formed by generally horizontal chambers that sit one above the other (to be described further below). The upper surface of the receiver box 38 is stepped creating two upper surface regions 35 , 37 . The upper surface regions 35 , 37 include receiver box inlet opening 58 and outlet opening 60 , respectively. These openings 58 , 60 are upwardly orientated. Extending from the uppermost surface region 35 is a triangular shaped box, or elbow 41 . The elbow 41 allows the connection of the generally horizontal top surface region 35 to the generally horizontally orientated inlet flexible duct section 42 .
[0063] The receiver box is positioned so that upon lowering of the HVAC module into the operating position, the inlet opening 50 and the outlet opening 52 align with the receiver box inlet 58 and outlet 60 , respectively. This can be seen in FIG. 4 where the HVAC module 22 is being lowered into position relative to the receiver box 38 . As the HVAC module 22 is lowered into the operating position, as shown in FIG. 5 , the downwardly facing inlet opening 50 and outlet opening 52 abut against the upwardly orientated inlet 58 and outlet 60 , respectively. The receiver box 38 includes two latch clamps 72 that align with latches 73 on the inlet and outlet hoods 51 , 53 . Once fully lowered, latch clamps 72 are fastened to latches 73 locking the HVAC module 22 to the receiver box 38 .
[0064] The receiver box inlet 58 and outlet 60 are created by a plurality of hexagonal apertures arranged to form honeycomb plates. The honeycomb plates may be integrally formed with the upper surfaces 35 , 37 or may be separate overlying plates. Such a honeycomb aperture structure maximises airflow whilst maintaining structural integrity to the top of the receiver box 38 and also provides sealing surface area. Located about the inlet opening 50 and the outlet opening 52 are seals 54 . The seals 54 typically comprise a pad of 5-10 mm thick low porosity neoprene foam. However it will be appreciated that any suitable seal may be utilised. As the HVAC module is fastened to the receiver box 38 , the seals 54 are clamped against the top surface of the receiver box 38 about the edge of the honeycomb plates. It will be appreciated that the seals could alternatively be connected to the receiver box.
[0065] A rear view of the clamped operating position is shown in FIG. 6 . A sectional front view is taken through lines A-A and shown in FIG. 7 . FIG. 7 illustrates the two flow paths through the receiver box 38 . Conditioned air from the HVAC modules travels along air flow path A into the operator cab 20 . The conditioned air flows out of the outlet opening 52 through the receiver box outlet 60 into the lower receiver box chamber 61 . From the receiver box chamber 61 the air flows to the outlet flexible duct section 46 , through the outlet fixed duct section 44 to the end 43 , and into the operator cab 20 . Return air from the operator cab 20 travels along the return air flow path B from the end 39 of the inlet fixed duct section 40 . The air travels along the inlet fixed duct section 40 to the receiver box 38 via the inlet flexible duct section 42 , turning at elbow 41 . The air enters the upper receiver box chamber 59 flowing to the receiver box inlet 58 through inlet opening 50 along hood 51 into the HVAC module 22 . As shown in FIG. 7A , a sealed connection is created between the HVAC module 22 and the receiver box 38 by downward clamping of the HVAC module 22 to the upper surface of the receiver box 38 . The seal 54 prevents the escape of air between the components.
[0066] To minimise the downtime of work machines if the HVAC module requires repair, the HVAC module is fully removable from the work machine. This is accomplished by employing releasable pivot hinges, where a pin 63 , held in by a circlip 65 , can be removed to allow disconnection, as best seen in FIG 8 . The gas strut 48 is connected to the housing with a ball joint, such that it can be quickly disconnected. The hydraulic hoses 64 , and electrical cables 68 , can be disconnected. The HVAC module can then be lifted out of the recess 16 and replaced by another HVAC module.
Industrial Application
[0067] Referring to FIGS. 8 and 9 , the internal components of the HVAC module 22 and operation of the HVAC system will be explained. FIG. 8 shows a top view of the lower box 24 with upper lid removed. The lower box 24 is partitioned into three regions using sheet steel walls. The three regions are the operational component region 74 , the condenser region 76 and the conditioning region 78 . This is diagrammatically illustrated in the boundary diagram of FIG. 9 .
[0068] The operation region 74 includes a hydraulic motor 80 and a hydraulic compressor 82 . The motor 80 drives the compressor 82 . The motor 80 draws hydraulic fluid from a hydraulic supply external to the HVAC module (typically associated with the work machine torque converter pump stack) and is regulated via a manifold 84 . The hydraulic fluid flow path E is illustrated in FIG. 9 .
[0069] Also housed in the operational region 74 are a high pressure charge port 86 and a low pressure charge port 102 , together with a receiver drier 96 . A thermal expansion valve 77 (commonly referred to as a TX valve) is also housed in this region. A number of pressure sensors 100 and temperature sensors 108 are also located in the operational region 74 . An electronic control module (ECM) 118 and a water valve 56 complete the preferred components housed in the operational region 74 . However, it will be appreciated that other components associated with the HVAC system may also be housed in the operational region.
[0070] The condenser region 76 contains a condenser 90 and two axial fans 92 . The axial fans 92 draw fresh air from the ambient environment through the vents 30 in the upper lid 26 . This air blows over the condenser 90 . The air is then ejected out of the lower vents 70 into the underlying transmission bay.
[0071] The conditioning region 78 includes an evaporator 94 , a heater core 114 and a blower 116 . Fresh air filter 106 and secondary filter 110 are also housed within the conditioning region, together with temperature sensors 108 . A fresh air inlet 104 is located in the sidewall of the lower box 24 (see FIG. 4A ). The evaporator typically communicates with the TX valve 77 , which regulates the flow rate through the evaporator, controlling the superheating of the refrigerant within the evaporator.
[0072] The components are generally adapted to work in concert to produce HVAC cooling and/or heating, as will be appreciated by those skilled in the art. The ECM is configured to control all aspects of the HVAC system, including the hydraulic components and electrical control functions, as illustrated in the boundary diagram in FIG. 9 by the dashed connection lines.
[0073] FIG. 9 schematically illustrates the refrigerant flow path C. Refrigerant in a gaseous state moves from the compressor 82 to the condenser 90 via high pressure charge port 86 and AC pressure sensor 100 . The refrigerant enters the condenser 90 where it is cooled from its superheated state and condenses into a cooled liquid phase. The liquid refrigerant passes through the receiver drier 96 , which dries the refrigerant, increasing the heat rejection capacity of the fluid. The refrigerant then passes through the TX valve 77 , which meters the amount of refrigerant flowing through the evaporator 94 , allowing a low entropy liquid and vapor mixed refrigerant to enter the evaporator. The refrigerant evaporates and returns to a gaseous state, gaining energy from the air flow, where it is returned to the compressor 82 via an AC pressure sensor and low pressure charge port 102 . The refrigerant continues to cycle through the flow path C.
[0074] Hot coolant is drawn from the engine cooling system of the work machine 2 and supplied to the heater core 114 . The engine coolant flow path D is illustrated in FIG. 9 whereby the hot coolant passes via a water valve to the heater core. The water valve is ECM position controlled, whereby the position of the internal ball valve controls the flow rate and hence heat exchange to the airstream. A receptacle 120 and relay 122 are required for the water valve 56 , to take the low-power signal outputs from the ECM 118 and boost the signal to the required voltage for the water valve solenoid to actuate.
[0075] Within the conditioning region 78 air is circulated. Fresh ambient air is drawn in through air inlet 104 in the front of the housing and passes through a fresh air filter 106 . Concurrently, return air is circulated back into the conditioning region 78 via inlet opening 50 . The mixed fresh air and return air is then passed via temperature sensor 112 through a secondary filter 110 . The filtered air is passed through the evaporator where it is cooled, if cooling is required in the operator cab 20 . It then passes through the heater core 114 , where it is heated, if heating is required in the operator cab 20 . Air at the desired temperature air is then blown into the outlet ducting by a blower 116 , which transfers the air to the operator cab 20 .
[0076] The advantage of utilising substantially fixed ducting is that the cross-sectional profile of the ducting is more controllable, enabling minimalisation of pressure loss from surface friction in the airstream and allowing turbulence control. Turbulence commonly exists in flexible hoses, particularly those that are ribbed. By limiting the amount of flexible ducting to a small section, the required flexibility between fixed bodies is provided to allow for vehicle movement and vibration, whilst minimising turbulence. Use of the static receiver box to create the duct interface with the HVAC module inlet and outlet ensures a good seal is maintained, whilst allowing the easy disconnection to move the housing into the maintenance position. By utilising opposing downwardly and upwardly orientated openings at the duct interface, a positive clamping force can be applied to ensure an equilibrant pressure across the seal interface, for optimal sealing and pressurisation.
[0077] Although aspects of the present disclosure were described with reference to underground loaders, it should be appreciated that many of the features and advantages described herein may have broad applicability across a wide range of machines. For example, many of the features described herein may be applicable to different types of loaders and trucks, whether for above ground or underground use.
[0078] It will be understood that the invention disclosed and defined in this specification extends to all alternative combinations of two or more of the individual features mentioned or evident from the text or drawings. All of these different combinations constitute various alternative aspects of the invention. | A heating, ventilation, and air conditioning (HVAC) module, for a HVAC system, mountable to a work machine, the HVAC module comprising a housing having at least one air outlet and at least one air inlet communicable with ducting on the work machine for conveying air into and out of the operator cab of the work machine. The module also includes a mounting assembly for pivotably attaching the housing to the work machine. The housing is moveable between an operating position where the outlet and inlet are in contact with a ducting interface on the work machine, and a maintenance position, where the housing is pivoted upwards to disconnect from ducting interface of the work machine to allow access to underlying components of the work machine. | 4 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This patent application claims priority to and is a continuation in part application of U.S. application Ser. No. 10/331,407, filed on Dec. 30, 2002, which is a continuation in part application of U.S. application Ser. No. 09/736,598, filed on December 13 , 2000 , and of which the entire contents of both are hereby incorporated by reference herein.
FIELD OF THE INVENTION
[0002] The present invention relates to a retaining wall block that is resistant to damage and wear caused by the environment it is placed into. The deterioration resistant block is generally a hollowed frame or shell of a deterioration resistant material that is light-weight and is configured to accept and retain any type of filling material. The filling material provides weight and stability to the retaining wall block and also provides weight, stability and security to a retaining wall constructed of such blocks.
BACKGROUND OF THE INVENTION
[0003] The use of retaining walls to protect and beatify property in all types of environmental settings is a common practice in the landscaping, construction and environmental protection fields. Walls constructed from various materials are used to outline sections of property for particular uses, such as gardens or flower beds, fencing in property lines, reduction of erosion, and to simply beautify areas of a property.
[0004] Numerous methods and materials exist for the construction of retaining walls. Such methods include the use of natural stone, poured in place concrete, masonry, landscape timbers or railroad ties. In recent years, segmental concrete retaining wall units, sometimes known as keystones, which are dry stacked (i.e., built without the use of mortar), have become a widely accepted product for the construction of retaining walls. Examples of such units are described in U.S. Pat. No. RE 34,314 (Forsberg) and in U.S. Pat. No. 5,294,216 (Sievert).
[0005] However, many of the materials utilized in the construction of retaining walls are susceptible to deterioration and/or are not very aesthetically appealing. The ability of these retaining walls to withstand sunlight, wind, water, general erosion and other environmental elements is a problem with most retaining wall products.
[0006] A particular concern is the utilization of erosion protection materials in water shorelines. Leaving the shoreline natural can lead to erosion, cause an unmanageable and unusable shoreline, create high maintenance, and inhibit an aesthetically pleasing property. Many materials utilized in retention of shorelines are subject to immediate deterioration and/or are not as aesthetically appealing as one would desire. Furthermore, many materials utilized on shoreline structures are difficult to maintain due to the awkward location in the water and also the prevalent growth and presence of organic materials that can get caught and flourish in such a structure. For example, many lakeshore or ocean side properties utilize riprap as a retention device for prevention of erosion. Riprap is a configuration of large to medium size stones placed along the shoreline. A problem with waterfront properties that use a continuous wall of typical riprap is the shoreline will retain some organic material or will accumulate additional organic material brought in by the water. This usually leads to an unmanageable and aesthetically displeasing shoreline or higher maintenance. Furthermore, the riprap is never uniform in color and size and therefore does not as provide the most aesthetically pleasing shoreline or complete coverage of the shoreline. The lack of uniform shoreline coverage allows for some erosion, collection of various materials and the growth of weeds.
[0007] Another problem with materials normally utilized in the construction of retaining walls, such as poured in place concrete, masonry, landscape timbers, railroad ties or keystones is that regulations in most states and counties prohibit their use in or near bodies of water because of the crumbling or deterioration of the material into the body of water over time. Many of these retaining wall materials dissolve, crumble, break apart and/or float into the body of water for which they line causing problems with the shoreline and pollution of the water. For example, the average life of a concrete block or keystone in water is approximately a couple of years. A need exists for a retaining wall, which would be resistant to such deterioration.
[0008] An additional concern that exists in the construction of retaining walls is the weight of the materials. Concrete blocks, large stones, timbers or keystones can be heavy to move into the wall location and maneuver when constructing the wall. Many locations for which retaining walls are constructed are positioned in awkward terrain. Heavy building materials are difficult to move into the location and furthermore are difficult to position when constructing the retaining wall thereby adding additional cost and labor for installation. However, the heavy materials are needed once the wall is constructed to provide stability and security to the structure. Therefore, the easy to install light-weight units used for the construction of a retaining wall, which can be weighted once placed into position thus retaining the block in position and stabilizing the completed retaining wall, would be beneficial to construction of such structures.
SUMMARY OF THE INVENTION
[0009] As previously mentioned the present invention relates to a retaining wall block that is resistant to damage and wear caused by the environment it is placed into. The deterioration resistant block is generally a hollowed frame or shell of a deterioration resistant material that is light-weight and is configured to accept and retain any type of filling material. The filling material provides weight and stability to the retaining wall block and also ultimately provides stability and security to the retaining wall constructed of such blocks. More specifically, the deterioration resistant block comprises a top panel, a bottom panel, a wall assembly and an optional anchoring device. One or more chambers are created by adjoining the top panel, bottom panel and wall assembly. The chambers are adapted for receiving and retaining fill materials. such as sand, dirt, gravel, pea rock, crushed rock, concrete or any other similar material, which provides the permanent weighting and stability of the retaining wall block.
[0010] Embodiments of the present invention are comprised of a deterioration resistant retaining block for use in constructing retaining walls on a number of property terrains, such as along waterfront properties. The deterioration resistant blocks are particularly useful for terrains near water or underwater due to their resistance to degradation. However, the deterioration resistant blocks could also be used for land applications for those that want a light-weight retaining wall block that can be filled on-site to add weight and stability and doesn't require heavy equipment for moving. Therefore, the deterioration resistant retaining wall block could be utilized to construct any form of wall or fence structure.
[0011] One unique feature of the present invention is the lightweight characteristic of the block before it is filled. As previously mentioned, embodiments of the present invention can be waterproof and may be filled with any type of fill material located at the site, such as rocks, sand, gravel, soil, pea rock, crushed rock or similar materials. The filling characteristic of the deterioration resistant block means that when the block is not filled it is very light-weight. The light-weight feature provides individuals constructing such walls the advantage of easily moving large numbers of the blocks to the site of construction with relative ease. Furthermore, the lightweight characteristic of the blocks allows for easy maneuvering of the blocks into final position when constructing the wall and still allows for the stability of a heavy block after it is filled. These characteristics are met by the block being made of a lightweight material and also configured to receive a heavy fill material once it is about to be placed or has been placed in its final position on the retaining wall.
[0012] Embodiments of the present invention further fills an unmet landscaping need for shorelines in that the deterioration resistant blocks are easily manufactured. Examples of possible manufacturing methods include but are not limited to injection-molding, thermoforming, compression molding and blow-molding. Also any high volume application for production may be utilized in manufacturing the present invention. The individual units are light-weight, attractive, easy to install, prevent shoreline and other terrain erosion and compliment existing retaining wall block. The deterioration resistant blocks are also waterproof, can withstand ice damage due to their flexible nature and are easily replaced in case of damage. Furthermore, they are rugged and very low maintenance. Additionally, embodiments of the present invention are easily transportable and storable due to their light-weight and possible stacking features.
[0013] Individuals would be more inclined to install block made of a deterioration resistant material themselves rather than cement block, timbers, keystones and the like, because of the ease of installation, due to the lightweight material and also the longevity of the block. The minimum weight of most regular garden block is approximately 30-50 lbs, whereas embodiments of the present invention may be approximately 0.1-10 lbs, in various embodiments 1-2 lbs. Of course, weight may vary depending on the size and materials utilized in manufacturing embodiments of the present invention. Also, as previously mentioned the blocks of the present invention retain the final stability and weight by filling the block with an appropriate fill material either prior to or after it has been permanently installed.
[0014] As previously suggested, embodiments of the present invention are also resistant to deterioration, such as wear, crumbling and breaking, therefore, the deterioration resistant block does not have to be replaced as often and/or increases the lifespan of the retaining wall. The block has approximately the lifespan of at least 5-10 times the life of a regular cement block made by the dry cement process such as the Keystone® style retaining wall block. The increased lifespan of the block translates to fewer or no occurrences of replacement of individual blocks or the potential complete reconstruction of the entire wall. Furthermore, retaining wall materials, such as concrete block, timbers and dry cement process block, are typically not used in water applications because they dissolve, crumble and/or break down over time and exposure. The durability and resistant characteristics of the present invention reduce and prevent this deterioration, therefore making it very beneficial for all applications that come in contact with water.
[0015] Another consideration relating to the water application of embodiments of the retaining wall block of the present invention is the block's resistance to ice damage when installed around a body of water when it freezes. When ice expands and/or moves it shifts, tears and damages various types materials utilized for shoreline retention, such as keystone, concrete block, rip rap, landscape timbers or anything rigid. Embodiments of the present invention can be manufactured with a material that has flexibility and would flex in a similar way as a Rubbermaidg trash can flexes. Considering that the deterioration resistant block would be filled with a fill material, the deformation would be minimal, but still enough to prevent damage to the retaining wall block and/or the entire wall. Furthermore, upon melting or shifting of the ice the deterioration resistant block would return to its original configuration.
[0016] Another advantage of embodiments of the present invention relates to the high cost of waterfront property and people's inclination to improve their property to keep it well-maintained and aesthetically pleasing. As previously mentioned riprap, is commonly stacked along property shorelines to prevent erosion. The trouble with this shoreline preservation application is that the rock leaves many crevices for organic material to reside and, since it is close to water, the crevices are prominent areas for the growth of vegetation. The advantage of embodiments of the present invention is that they fit next to each other and prevent organic material from getting in-between the blocks, therefore preventing vegetation from growing in such structures.
[0017] In addition, many waterfront properties suffer water damage when water levels rise above the shoreline. The retaining wall block of the present invention is a solution to water retention and erosion problems in such areas of threatening high or rising water levels. Furthermore, the retaining wall block poses a solution in locations where there is a flood plane or areas that are washed out by any type of water movement. Sandbags have been a solution to such problems, but are not a permanent or aesthetically pleasing solution. The retaining wall block can replace sand bags in an area for which a more permanent and aesthetically pleasing alternative is desired.
[0018] As previously suggested, the deterioration resistant retaining wall block can comprise any type of shape, configuration, color and design. In addition the retaining wall block may include any design or color located anywhere on any panel or wall of the block. Furthermore, the utilization of conventional type materials for retaining walls, such as concrete blocks, timbers or concrete retaining wall blocks, are heavy to install and may not provide long term or permanent solutions, due to the previously mentioned deterioration problems. Therefore, the present invention provides an aesthetically pleasing solution and replacement for materials, including sandbags, presently utilized in retaining wall construction.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] FIG. 1 depicts a perspective view of one embodiment of a deterioration resistant retaining wall block.
[0020] FIG. 1A depicts a perspective view of one embodiment of a deterioration resistant retaining wall block that includes a top panel that has a front section.
[0021] FIG. 1B depicts a top view of one embodiment of a deterioration resistant retaining wall block that includes a wall assembly that includes waved wall panels.
[0022] FIG. 1C depicts a top view of one embodiment of a deterioration resistant retaining wall block that includes a interlocking knob and depression.
[0023] FIG. 2A depicts a perspective view of one embodiment of a deterioration resistant retaining wall block that includes a split top panel having teeth.
[0024] FIG. 2B depicts a perspective view of one embodiment of a deterioration resistant retaining wall block that includes a split top panel having intertwining fingers.
[0025] FIG. 2C depicts a perspective view of one embodiment of a deterioration resistant retaining wall block wherein the front section includes a plurality of teeth.
[0026] FIG. 3 depicts a side view of a deterioration resistant retaining wall block, which includes a retaining flange.
[0027] FIG. 4 depicts a perspective view of one embodiment of a deterioration resistant retaining wall block that includes a wall reinforcement fastener in the form of rivets.
[0028] FIG. 4A depicts a side view of one embodiment of a deterioration resistant retaining wall block that includes a wall reinforcement fastener in the form of rivets on the top panel and flange.
[0029] FIG. 4B depicts a perspective view of one embodiment of a deterioration resistant retaining wall block that includes a wall reinforcement fastener in the form of tack strips.
[0030] FIG. 4C depicts a perspective view of one embodiment of a deterioration resistant retaining wall block that includes a wall reinforcement fastener in the form of a grid retention rod system.
[0031] FIG. 4D depicts a perspective view of one embodiment of a deterioration resistant retaining wall block that includes a geogrid fabric adjoined to the block.
[0032] FIG. 5A depicts a front view of a deterioration resistant retaining wall block, which includes insertable pegs.
[0033] FIG. 5B depicts a perspective view of deterioration resistant retaining wall blocks, which includes an aperture in the form of a trough for receiving lockable insertable pegs.
[0034] FIG. 6 depicts a perspective view of the bottom panel of a deterioration resistant retaining wall block, which includes insertable pegs.
[0035] FIG. 6A depicts a perspective view of the bottom panel of a deterioration resistant retaining wall block, which includes conduit insertable pegs that include protrusions.
[0036] FIG. 7 depicts a perspective view of the bottom panel of a deterioration resistant retaining wall block, which includes insertable pegs that slide within a mounting tray.
[0037] FIG. 8 depicts a perspective view of deterioration resistant retaining wall that depicts the pegs of one embodiment of a block being lowered into the apertures of two blocks positioned below.
[0038] FIG. 9A depicts a perspective view of deterioration resistant retaining wall that includes staggered rows and a stabilizing rod and geogrid system adjoined to the wall.
[0039] FIG. 9B depicts a perspective view of deterioration resistant retaining wall that includes staggered rows and molded designs on the front panel.
[0040] FIG. 10 depicts a perspective view of a deterioration resistant retaining wall block containing multiple chambers.
[0041] FIG. 11 depicts a top view of a multiple chamber deterioration resistant retaining wall block that includes a top panel with multiple apertures.
[0042] FIG. 12A depicts a perspective view of a cover of a deterioration resistant retaining wall block.
[0043] FIG. 12B depicts a perspective view of a cover with extended overlapping panels form fitted over a deterioration resistant retaining wall block.
[0044] FIG. 12C depicts a perspective view of a cover with an extended overlapping panel having a front face with an apron form fitted over a deterioration resistant retaining wall block.
[0045] FIG. 13A depicts a side view of a deterioration resistant retaining wall block including a hingedly attached cover.
[0046] FIG. 13B depicts a perspective view of a deterioration resistant retaining wall block including recessions for receiving tabs of a cover.
[0047] FIG. 13C depicts a side view of a deterioration resistant retaining wall block including a hingedly attached cover.
[0048] FIG. 13D depicts a side view of a deterioration resistant retaining wall block including a hingedly attached split cover.
[0049] FIG. 14 depicts a top view of a partial section of a deterioration resistant retaining wall block.
[0050] FIG. 14A depicts a perspective view of a block end cap.
[0051] FIG. 14B depicts a perspective view of one embodiment of a block including cap hooking devices.
[0052] FIG. 14C depicts a perspective view of one embodiment of a cut block including a trimmed section and a visible section.
[0053] FIG. 14D depicts a perspective view of one embodiment of a cut block including a trimmed section nested within a visible section.
[0054] FIG. 15 depicts a top view of a multi-unit deterioration resistant retaining wall block, which includes disengaging tabs.
[0055] FIG. 16 depicts a front view of a multi-unit deterioration resistant retaining wall block.
[0056] FIG. 17 depicts a top view of a multi-unit deterioration resistant retaining wall block with disengaged tabs.
[0057] FIG. 18 depicts a top view of a deterioration resistant retaining wall block that includes interlocking clips and pockets.
[0058] FIG. 19 depicts a perspective view of more than one stackable deterioration resistant retaining wall blocks.
[0059] FIG. 19A depicts a side view of a deterioration resistant retaining wall block including a hingedly attached top panel and bottom panel.
[0060] FIG. 19B depicts a perspective view of a row of a deterioration resistant retaining wall that includes an inner block that is top side down and two outer blocks that are top side up.
[0061] FIG. 20 depicts a perspective view of one embodiment of a partial row of deterioration resistant capping blocks.
DETAILED DESCRIPTION OF THE INVENTION
[0062] FIG. 1 depicts one embodiment of the deterioration resistant retaining wall block 10 comprising a top panel 12 , a bottom panel 14 and a wall assembly 16 . FIG. 1 illustrates one embodiment of the present invention that includes a top split panel 12 , which includes a back section 18 and a front section 20 . It is noted that a number of embodiments included in the present invention may include a top panel 12 that is not split. The top split panel 12 may also include one or more apertures 22 . The apertures 22 may be of any size and shape suitable for receiving one or more anchoring devices as will be described below. The bottom panel 14 includes a relatively flat surface or contoured to rest uniformly with the top panel 12 of one or more blocks 10 positioned below. In other embodiments of the present invention the top panel 12 and bottom panel 14 may include apertures 22 that align with apertures positioned on the top panel and bottom panel of adjacent blocks above and below. Such alignment of apertures 22 allow for the intermingling of fill material that may add additional friction between the blocks and may provide a potential securing feature for geogrid fabric positioned between rows of blocks.
[0063] In an alternative embodiment, as depicted in FIG. 1A , the top panel 12 comprises only one section, such as a front section 20 , that does not extend across the complete top area of the block 10 . However, in one embodiment this section will extend far enough along the top of the block to be covered by one or more blocks that are placed in the row above such a block. Such a partial tip panel generally extends to a distance wherein the fill material is not exposed to the exterior of the wall when a row of block is positioned over another row of block. In various embodiments the block may further include stability strands 23 , which interlock the front section 20 of the block 10 to the back of the wall assembly 16 . These strands 23 may be made of any durably strong material, such as metal wire, plastic, and the like. Furthermore such strands 23 may be integrated with the front section 20 and/or the back of the wall assembly 16 or may be attachable by any means know in the art (e.g. hooks, clamps, rivets . . . ). In one embodiment the strands 23 may be the remaining plastic in a full top panel that includes one or more apertures (e.g. apertures formed in the top panel that leave a strand of plastic extending down the middle and/or strands extending along each side of the wall assembly including the back of the wall assembly). Also, the blocks, as depicted in FIG. 1A , may further include apertures 22 that allow for the intermingling of fill material from the blocks positioned above and below with the fill material of a block positioned between.
[0064] Also, the front of the block 10 of the present invention, as depicted in the FIG. 1A , may further include a design, such as the appearance of multiple bricks or blocks. This allows for the installation of larger blocks in a wall that appears to a multitude of bricks or blocks.
[0065] As previously mentioned, the deterioration resistant retaining block 10 also includes a wall assembly 16 , which is also depicted in FIG. 1 . The wall assembly 16 comprises one or more outside wall panels 24 . Many embodiments of the present invention include wall assemblies 16 that are adjoined to the top panel 12 and bottom panel 14 . The adjoinment of the wall assembly 16 to the top panel 12 and bottom panel 14 creates a chamber 26 located within the retaining block 10 . The chamber 26 is normally filled with materials such as sand, gravel, dirt, concrete, crushed rock, pea rock or other like materials to provide weight and structure stability to the retaining block 10 and the entire retaining wall.
[0066] In another embodiment of the present application the wall assembly 16 may include a block interlocking mechanism, such as waved side walls or an interlocking knob and depression. FIG. 1B depicts one embodiment of the present invention wherein the wall assembly 16 includes one or more wall panels 24 that are waved. The waving of the wall panels 24 allows for adjacent blocks to interlock with each other when a wall is being curved. In alternative embodiment, as depicted in FIG. 1C , the blocks 10 may include a knob 27 on one wall panel 24 and a depression on the opposite wall panel 29 . Similar to the waving of opposite wall panels, the knob 27 and depression 29 allow for the interlocking of adjacent blocks 10 .
[0067] Additionally, the wall assembly 16 will generally include a front face 17 that is visible to an observer when a wall is constructed from the blocks 10 of the present invention. In various embodiments of the present invention the front face 17 will have a natural earthen appearance simulating the color and texture of earth environments. For example, the front face may be colored and textured to have the appearance of rock, stone, sand, soil, clay, trees and foliage, water, or any other natural environment type look. Additionally, in additional embodiments the front face 17 may further include one or more designs (e.g. symbols, company names, logos, images) that may be positioned in the natural earthen appearance (e.g. the NTR logo embedded in a stone color and texture).
[0068] FIGS. 2A and 2B depict various embodiments of a top split panel 12 . As depicted in FIG. 2A , one embodiment of a top split panel 12 of the present invention comprises a second section 20 having a plurality of teeth 28 . The teeth 28 may extend downward from the second section 20 when in a closed position and may be utilized to engage one or more wall stabilization devices (not shown), such as geogrid or geowebbing. It is noted that the teeth 28 may be considered a wall reinforcement fastener (a further explanation of wall reinforcement fasteners will be described below). The second section 20 may abut flush to the front edge of the back section 18 of the top split panel 12 as illustrated in FIG. 1 or may overlap and/or engage the back section 18 . One embodiment of the engagement of the top panel section is depicted in FIG. 2A . As depicted in FIG. 2A , the back section 18 may include a plurality of notches 30 , which receive and engage the teeth 28 of the second section 20 when the split top panel 12 is in the closed position.
[0069] FIG. 2B illustrates another embodiment of the present invention wherein the top split panel 12 includes a back section 18 and a front section 20 with intertwining fingers 32 that alternate with each other when the top split panel 12 is in the closed position.
[0070] FIG. 2C depicts another embodiment of the present invention, similar to the block 10 depicted in FIG. 1A , wherein the front section 20 includes a plurality of teeth 28 . The teeth 28 generally operate to anchor the front section 20 into the fill material and also may be utilized to engage one or more wall stabilization devices, such as geogrid or geowebbing.
[0071] In various embodiments of the present invention, the bottom panel 14 may optionally include or be adjoined to a flange 34 . FIG. 3 depicts the side view of an embodiment of the present invention, which includes a retaining flange 34 adjoined to the bottom surface 14 of the block 10 . On a constructed wall, each retaining flange 34 is a wall retention device that operates to align the block being placed with the row below and generally inhibits outward movement of the wall. Normally, the retaining flange 34 extends downward from the back of the bottom panel 14 and rests against the back of the retaining block 10 located below the bottom panel 14 . The retaining flange 34 may be a unitary piece extending downward from the back of the retaining block 10 or may be a series of fingers (not shown) extending downward from the back of the retaining block 10 .
[0072] The retaining block 10 of the present invention may also include a means for attaching wall stabilization devices, such as geogrid. FIG. 4 depicts one embodiment of a wall reinforcement retention device 38 comprising a plurality of rivets 40 operably adjoined to the front section 20 of the top panel 12 of a retaining wall block. FIG. 4A depicts an embodiment of the block including the rivets 40 positioned on the top panel 12 and flange 34 . However, it is noted that the rivets 40 may be positioned anywhere on the block, which is optimum to hook and retain the webbing of a geogrid or other device that extends back from the wall into the slope being protected. The rivets may be of any size and shape, which optimize the attachment of the geogrid or other devices reinforcing the wall structure.
[0073] FIG. 4B depicts another embodiment of a wall reinforcement retention device 38 in the form of tack strips 42 . Tack strips 42 generally include a series of projections 44 that angle away from the force exerted by the geogrid. The geogrid is normally hooked by the projections 44 and extends back into the slope. It is noted that in embodiments that include a top split panel 12 the projections are generally attached to the second section 20 , which tend to pull the front of the block 10 back towards the slope.
[0074] Yet another embodiment of a block 10 of the present invention which includes a wall reinforcement device 38 is depicted in FIG. 4C . FIG. 4C depicts a top panel 12 that includes a front panel 20 having an elongated member 46 . In this embodiment the elongated member 46 extends the width of an edge of the second section 20 of the top panel 12 . The elongated member 46 may be a section of textured environment resistant material, such as a plastic rod, that may be integral with the second section 20 . The second section 20 in this embodiment may further include a ridge 48 positioned a distance from and running parallel with the elongated member 46 , which thereby forms a groove 50 sized to receive and retain a grid retention rod 52 . The ridge 48 may be a continuous structure of polymeric material or may be a series of pegs spaced apart from each other, but spanning the length of the second section 20 .
[0075] In operation, the wall reinforcement fastener 38 depicted in FIG. 4 functions by extending a section of geogrid fabric 54 over the back section 18 of a block 10 and under and around the rod 52 . Once around the rod 52 , the geogrid fabric 54 extends back towards the slope and the rod 52 is positioned in groove 50 . The wall reinforcement retention device 38 depicted in FIG. 4 generally holds the geogrid 54 in place by positioning the elongated member 46 , ridge 48 and rod 52 within a channel 56 positioned on a lower panel 14 of a block when the block is lowered onto the top panel 12 of a block below.
[0076] Finally, another embodiment of a wall reinforcement retention device 38 that may be utilized with blocks 10 of the present invention may be to integrate the geogrid fabric 54 with the block 10 . Integration of the geogrid 54 to the block 10 may be done by utilizing a fastener or means to fasten the geogrid fabric to the block or by molding the geogrid 54 directly into the block 10 . This may be done by utilizing any fastening means know in the art, such as adhesives, staples, solvent welding, clips, rivets and any other fastening means, which would retain the fabric 54 to the block 10 . FIG. 4D depicts an embodiment of the present invention wherein the geogrid 54 is integrated into the top panel 12 the block 10 . Alternatively, it is noted that the geogrid may be integrated into the bottom panel 14 or wall assembly 16 , such as the back wall panel.
[0077] The retaining wall block 10 of the present invention may further include one or more anchoring devices that interlock the blocks and rows of the constructed retaining walls utilizing such blocks 10 . FIG. 5A depicts one embodiment of the present invention wherein the anchoring devices include one or more insertable pegs 58 . The pegs 58 may be inserted into apertures 22 shaped similar to the pegs 58 or in a slightly oblong configuration to accommodate adjacent block fitting issues that may arise during construction of a wall. Alternatively, the insertable pegs 58 may also be received by a block 10 position below that includes a single aperture 22 that is in the shape of a trough 59 that extends across the width of the top panel 12 as depicted in FIG. 5B . In one embodiment of the present invention, the trough may be positioned between the back section 18 and front section 20 of the top panel 12 . In various embodiments the pegs 58 may be closed structures or, alternatively, open conduits that allow for the flow of fill material from one block to the blocks positioned below.
[0078] In FIG. 5A the insertable pegs 58 are positioned on the bottom panel 14 and are configured to be securely receivable in the apertures 22 of one or two top panels 12 of one or two adjacent retaining blocks 10 positioned below. The insertable pegs 58 can be made of any shape and size, which can be securely fit into the apertures 22 of the top panel 12 and optionally penetrate into the fill material of the block below. For example the pegs may be shaped as a cone or rod, wherein the bottom of the peg is pointed to better penetrate the fill material inserted in the block below. The insertable pegs 58 may also function to seal the interior of the below adjacent retaining block 10 from outside elements.
[0079] FIGS. 6 and 7 depict other types of peg configuration. FIG. 6 illustrates a bottom panel 14 of one embodiment of the present invention wherein the insertable pegs 58 are aperture inserts. Each insertable peg 58 of this embodiment includes a peg extension 60 which extends down from a sealing panel 62 . In operation, the peg extensions 60 are placed into an aperture 22 , which is position on the bottom panel 14 of a block. The aperture 22 may be oblong to accommodate lateral movement of the insertable peg 58 so that it may line up with a corresponding aperture on the top panel of a block positioned below. The sealing panel 62 will be generally larger than the aperture 22 positioned on the bottom panel 14 to properly seal the aperture 22 when the insertable pegs 58 adjoined to a block are locked into position on the wall. The insertable pegs 58 will be set into position upon entry into the aperture and fill material of the block below and with the weight of the fill material upon filling the block of which the insertable pegs are placed. The insertable pegs 56 may be solid in structure or may be an open conduit for the intermingling of fill material from one block to the next. Such intermingling of fill material may be beneficial in adding extra friction between blocks and thereby increase their connectivity.
[0080] In an alternative embodiment, wherein the insertable pegs 56 include an open conduit as depicted in FIG. 6A , the peg extensions 60 may comprise a plurality of protrusions 64 extending from the sealing panel 62 . The protrusions 64 may be pointed to better penetrate the fill material of the block positioned below and together may form the general shape of the aperture they project from.
[0081] In an alternate embodiment, as depicted in FIG. 7 , the insertable pegs 58 may slide within a mounting tray 66 positioned on the bottom panel 14 . The sealing panel 62 is generally sized to fit within the mounting tray 66 so that the panel 62 is retained within the upper tray edges 68 and slides freely in a lateral movement within the tray 66 . The lateral movement of the peg 58 will be available until the peg 58 is placed in an aperture 22 of a top panel 12 of a block positioned below.
[0082] In operation a block 10 is maneuvered so that the pegs 58 of one block 10 are inserted into the apertures 22 of one or more blocks. FIG. 8 illustrates a block 10 , which includes insertable pegs being lowered into the apertures 22 of two blocks 10 positioned below. This application is beneficial if the blocks of adjacent rows are staggered in positioning. See FIGS. 9A and 9B for an illustration of a staggered retaining wall. The interlocking of the blocks assists in vertical and horizontal connectivity of a constructed wall.
[0083] FIG. 9A depicts another embodiment of the present invention wherein a plurality of stabilizing rods 70 are extended through the apertures 22 of the blocks 10 to further interlock the blocks 10 and rows of block into position on the wall. Additionally, the stabilizing rods may further be utilized to retain geogrid fabric 54 that is positioned between the rows of block and extends back into the slope adjacent to the wall.
[0084] Another embodiment of the present invention is depicted in FIGS. 10-11 . The embodiment shown in FIG. 10 comprises a deterioration resistant retaining block 10 with the top panel removed, wherein the wall assembly 16 defines more than one chamber 26 within the retaining block 10 . The multiple chambers 26 are defined by interior partitions 28 . The interior partitions 72 may also be utilized to add additional support to the retaining block 10 to prevent any possible crushing of the block 10 . The interior partitions 72 may also act as wall panels if the block is cut to accommodate partial blocks for properly fitting a wall. FIG. 11 depicts one embodiment of the top panel 12 of a partitioned retaining block 10 . The interior partitions 72 are within the interior of the retaining block 10 and are depicted by dashed lines. The top panel 12 in this embodiment is permanently fixed to the wall assembly 16 and includes one or more apertures 22 or a trough (not shown) that may accommodate filling of each individual chamber 26 with appropriate fill material, such as sand, gravel, soil, cement or any other suitable material or may be utilized to receive pegs for anchoring the other blocks of a wall into position.
[0085] FIG. 12A depicts another possible embodiment of the top panel 12 , which is configured in a cover formation that may be adapted to securely fit over the retaining wall block 10 illustrated in FIGS. 1 or 10 . The top panel 12 of this embodiment comprises a closed section 74 that includes overlapping panels 76 , which overlap securely over the outside walls of a wall assembly 16 , but does not include apertures. However, the top panel may also secure to the wall assembly 16 in other ways, such as locking tabs, twist locks, clamps, clips, adhesives or any other fastener. The top panel may further include optional top partitions 78 to fit over wall panels if a block 10 is cut to form partial blocks.
[0086] The top panel 12 may also be manufactured so that the overlapping panels 76 are sized to completely cover the wall assembly 16 and/or the front panel 80 of the block 10 . FIG. 12B depicts an embodiment of a block 10 wherein the top panel 12 includes overlapping panels 76 that extend over the wall assembly 16 of the block 10 . In various embodiments, the overlapping panels 76 or front face 82 may also include designs or textures that provide a rock or stone appearance. As in other embodiments the overlapping panels 76 and/or front face 82 may include any design or color that may be molded or blended into the polymeric material. The block 10 may further include a ridge 82 that extends around the base of the block 10 to receive the edges of the overlapping panels 76 of the top panel 12 after filling of the block 12 and closing with the top panel 12 .
[0087] An alternative embodiment of a block 10 of the present invention that includes overlapping panels is depicted in FIG. 12C . The embodiment in FIG. 12C includes a top panel 12 having an overlapping panel in the form of a front face 82 that extends substantially over the front of the block 10 and may include a design or texture, such as a rock or stone appearance. The front face 82 may also include an apron 91 that extends back from the front face 82 and is received and surrounds the front of the block 10 when the top panel is placed over the block 10 . The top panel 12 may further include a wrap around latching device 93 that extends around the back of the block 10 and hooks or secures the top panel 12 in position when the top block 10 is closed or sealed. The top panel 12 may further include overlapping tabs 89 that may extend from the side edges of the top panel and are received by recesses 87 positioned on the side panels of the block 10 . Furthermore, the production of such a block with an overlapping front face may allow for the block portion to be prepared from a lower grade material (e.g. recycled plastic) and/or without additives, such as color or UV light stabilizers and the top panel 12 with an overlapping front face to be made with such additives. However, it is noted that in various embodiments the entire block, including top panel and overlapping front face, may be made of recycled plastic.
[0088] In other embodiments of the present invention, the top panel 12 may optionally be hingedly secured to the retaining block 10 by any type of hinge device 86 , thereby providing a unitary configuration of the retaining wall block 10 . For example the hinge device 86 may be a living hinge wherein the hinge is a section of scored plastic that provides a folding point for the top panel 12 . However, it is noted that any type of hinge may be utilized. FIG. 13A depicts one embodiment of the present invention including a top panel 12 hingedly adjoined to a front panel of the retaining wall block 10 . It is noted that the top panel 12 may be hingedly attached from any wall panel 24 of the block including the back, sides or front. The hinging of the top panel 12 to the front or side panels of a block 10 may provide filling benefits by allowing greater ease in filling the blocks 10 during the backfilling of fill material behind the wall being constructed. It is also noted that in various embodiments the top panel 12 may be stationary or fixed to the block 10 and other panels of the block may be hingedly attached so that these panels may be opened to accommodate the filling of the block 10 . For example, the back panel or a side panel may be hingedly attached to the top or bottom panel so as to allow the back of the block or the side of the block to receive fill material before closing and placing into position.
[0089] In another embodiment of the present invention the block 10 may include one or more recesses 87 for receiving overlapping tabs 89 that fit over and within the recesses 87 . FIG. 13B depicts one embodiment of a block 10 that includes recesses 87 . The recesses 87 may be of any shape or size, but are generally of a depth so that the overlapping tabs 89 , when received to no expand the width of the upper portion of the block 10 . FIGS. 13C and 13D depict two embodiments of top panels 12 that include overlapping tabs 89 . FIG. 13C depicts a one piece top panel that may include a hinge 86 , such as a living hinge that is an integrated plastic hinge, and the overlapping tabs 89 . It is noted that in various embodiments the top panel 12 may be disengaged or separated from the block, but still include tabs 89 on any of the edges of the panel 12 for engaging the recesses of the block 10 . FIG. 13D includes a top panel 12 that includes a back section 18 and front section 20 . Each section 18 , 20 include hinge devices 86 and tabs 89 that hold the position of the split top panel 12 within the recesses. It is noted that the overlapping tabs 89 may provide additional structural support for a filled block by inhibiting the top portion of the block from bulging after filling with a fill material.
[0090] As previously mentioned, multiple chambers 26 allow for the retaining block 10 to be cut, either at installation or during manufacture, into various shapes and still maintain a chamber that can receive and retain fill materials. FIG. 14 depicts a section of the retaining block 10 as shown in FIG. 10 wherein the corners have been removed and the block 10 has been cut in half. However, a block may be configured to be cut into any size block (e.g. quarter block, half block, three quarter block . . . ). The ability to cut the retaining block 10 and still retain the same features is particularly useful in preparing ends and awkward segments of retaining walls. Dashed lines depicted in FIG. 12 illustrate one embodiment of alternate cover configurations to conform to the various shapes of a retaining block 10 or portions thereof.
[0091] In an alternate embodiment, a block 10 may be cut and sealed with an end cap 77 . The end cap 77 will generally include a sealing section 79 and a block hooking device 81 for securing the sealing section 79 to the block. In one embodiment of the present invention, as depicted in FIG. 14A , the wall hooking device 81 is in the form of a wall section. A wall section normally traverses around or partially around the perimeter of the sealing section 79 and either may extend over the top panel, bottom panel, front face and back panel of a block or may extend within the block and contact the interior of one or more of these panels. The end cap 77 , as depicted in FIG. 14A , depicts an end cap 77 that includes a wall section that extends within the interior of the block 10 and further includes a hooking crest 85 that may engage one or more hook receiving devices 83 positioned within a block. The hooking crest 85 may be a crest that extends around the entire interior edge of the end cap 77 or may be a plurality of tabs positioned around the periphery of the interior edge of the end cap 77 . FIG. 14A depicts the embodiment with a plurality of tabs as the hooking crest 85 . An example of a block 10 that includes one or more hook receiving-devices 83 is depicted in FIG. 14B , wherein a series of ridges are present within the interior of the block 10 .
[0092] In yet another embodiment, a partial block may be formed by cutting a block 10 into two separate sections, trimming one of the sections, forming a slot in the trimmed section and nesting the trimmed section into the other section. FIGS. 14C and 14D depict one embodiment of a nested partial block. As depicted in FIG. 14C , a block 10 is cut into two sections 11 and 13 . One of the sections is then trimmed to allow for the nesting of the trimmed section 11 within the other section that is visible when placed in a wall, the visible section 13 . FIG. 14D depicts the trimmed section 11 being nested within the visible section 13 . Generally, the majority of the trimmed section 11 will be trimmed and nested completely within the visible section 13 , with the exception in some embodiments of the back panel of the trimmed section 11 , which may rest outside the back panel of the visible section after nesting. A slot 15 may be cut in the back of the bottom panel 14 of the trimmed section 11 to allow the back wall panel 24 of the trimmed section 11 to extend behind the back wall panel 24 of the visible section 13 . The two back panels 24 and/or front faces 17 may optionally be secured together following insertion of the trimmed section 11 within the visible section 13 . The back panels 24 and front faces 17 The back panels may be secured by any securing means known in the art, such as rivets, screws, clips, adhesives and the like.
[0093] In operation utilizing one embodiment of the present invention, a block 10 may be cut in a straight line alone one of the hook receiving devices 83 , such as a ridge. Next the cap 77 is inserted into the side of the cut end of the block 10 and the hooking device 81 , such as a wall section with a crest 85 , is allowed to hook a hook receiving device 83 , such as a ridge, adjacent to the cut line. Caps 77 may be manufactured to properly fit either side of the block depending upon which side requires cutting. It is noted that the cap 77 may include other alternative hooking devices 83 , such as recesses and tabs, or hook and piles, to secure the sealing section 79 into a secure position and maintain the fill material within the chamber 26 .
[0094] An additional embodiment of the present invention is depicted in FIGS. 15 and 16 . FIG. 15 illustrates a top view of a multi-unit retaining wall block 88 wherein multiple units 90 are incorporated into a single block 88 . A single multi-unit block 88 provides the appearance of multiple retaining blocks present in a single structure. The top panel 12 may be a single sheet or multiple sheets of material which may be adapted to cover each unit 90 and optionally may include apertures 22 . The interior of the retaining block 88 of this embodiment includes one or more interior partitions 72 . Removable tabs 92 may be positioned between the partitions to properly space the blocks and hold the individual units 90 together. The tabs 92 may be a simple piece of plastic or other polymeric material that may be removed by cutting or breaking to free the individual units 90 or maneuvering them if a rounded wall is desired.
[0095] FIG. 16 depicts the front view of the multi-unit retaining block 88 , which has the appearance of multiple separate units or blocks 90 . These multiple separate units 90 provide the appearance similar to the partial assembly of a retaining wall comprising a plurality of individual blocks, such as depicted in the walls of FIGS. 9A and 9B . The multi-unit retaining block 88 may include a top panel 12 that is a unitary structure or may include multiple covers, such as a multi-unit block 88 including multiple separate top panels similar to the top panel depicted in FIG. 12 or a hinged panels similar to that depicted in FIG. 13 .
[0096] FIG. 17 depicts another embodiment of a multi-unit retaining wall block 88 , wherein a few of the tabs 92 in the back have been collapsed inward on pivot points on the tabs and the multiunit block has been rounded. It is noted that in other embodiments the tabs may be removed by cutting to also perform the rounding function. In this embodiment of the present invention, tabs 92 may be positioned between each individual unit 90 on the front, middle and/or back of the multi-unit block 88 . If a curved wall is desired, the tabs 92 may be disengaged, collapsed or extended, thereby allowing one or more multi-unit blocks 88 to be maneuvered into a curved position. It is noted that the tabs 92 may include one or more hinges to allow for the rotation of each unit 90 while maintaining their connection or the hinges may be disengaged to allow for separation of the units 90 .
[0097] FIG. 18 depicts an additional embodiment of the present invention, similar to hook and pile attachments, wherein the retaining wall block 10 includes an interlocking feature that comprises a clip 94 and optional pocket 96 . In such an embodiment one or more clips 94 may extend from one side of a retaining wall block 10 over another side of an adjacent retaining wall block into a trough or one or more corresponding pockets 96 . Such interlocking mechanisms provides for a overall secure retaining wall structure by reducing the amount of lateral movement that may occur with unsecured stacking of individual blocks.
[0098] In various embodiments of the present invention the blocks may be nestable for stacking. Various embodiments of the present invention, such as those depicted in FIG. 19 , also provide for ease in transport and storage of large numbers of these blocks due to stackable features. An additional example of a stackable retaining block 10 may be similar to that as shown in FIG. 1 , wherein the top panel 12 is removable or hinged and allows for the retaining block 10 to be inserted within the chamber 26 of another block 10 . Generally the slight sloping of the wall assembly allows for the nesting of such blocks. Angles of the wall assembly may vary, but generally include a 1° to 15° angle, preferably 2° to 5°. The top panel 12 for such a retaining block 10 may include a cover similar to any of the top panels 12 shown in the Figures herein.
[0099] To provide a more uniform fit when placing the blocks of the present invention in a retaining wall, some embodiments of the present invention may include removable or hinged top and bottom panels. FIG. 19A depicts one embodiment of a block 10 of the present invention wherein the top panel 12 and bottom panel 14 are adjoined to the block with hinges 86 . The hinges may comprise any type of hinge including, but not limited to, living hinges. The presence of two hinged panels provides for the filling of each block 10 from either the top or bottom panel 12 , 14 . Such filling options allows for the gap between adjacent blocks, due to the sloping of the wall assembly, to be offset by positioning adjacent blocks in alternating top panel up and top panel down positions. FIG. 19B depicts one row in a wall wherein the middle block is top panel down and the two outer blocks are top panel up, thereby matching the slopes of the side panels and offsetting the gaps caused by the slope of each adjacent block. Finally, in various embodiments of the present invention adjacent blocks above and below may be further linked by including pegs 58 and troughs 59 or apertures (not shown) in the top panel 12 and bottom panel 14 .
[0100] As previously mentioned, the present invention may be manufactured from a deterioration resistant, substantially rigid composite or polymeric material including, but not limited to, plastic, a rubber composition, fiberglass, or any other similar material or a combination thereof. Preferable materials are light-weight and slightly flexible. In various embodiments of the present invention plastics, such as high density or low density polyethylene, polypropylene or plastic polymer blends may be utilized. Furthermore, plastics that include additives such as wood fibers or clay may be used in the process to form the blocks of the present invention. Generally, the embodiments of the present invention may comprise any type of material that would have the similar characteristics to plastic, vinyl, silicone, fiberglass, rubber or a combination of these materials. However, it is noted that the material utilized in the present invention should be rigid enough to hold its form upon addition of filling material and also when placed in contact with other objects. Another preferable material may be comprised of a material similar to that utilized in the production of some types of garbage cans or the utilization of recycled rubber from objects such as tires. Such materials would be capable of holding rigidity and still offer flexibility when placed in contact with other objects, such as other retaining wall blocks or ice. Also, such materials have the ability to regain its original form when the object or material has been removed.
[0101] Embodiments of the present invention may also vary in appearance. Since embodiments of the present invention may be manufactured by a process such as injection molding, the molds may include any type of design, texture or shape. For example, the front face and top panel of blocks may be textured and colored to take on the appearance of stone or rock formations. Furthermore, the front panels of the retaining wall block 10 could be molded in almost any type of configuration. Examples of designs are depicted in FIGS. 8 and 9 A. In one embodiment, multiple retaining wall blocks could be molded to include designs that, when positioned on a retaining wall, would complete a larger single design, such as the spelling of a company or school name in large letters or the completion of a large image. Also, since the present invention may be manufactured from a number of different products, such as plastic, a rubber composition or fiberglass, the retaining wall block may comprise any color or a multitude of colors. For example, a retaining wall installed in a beach setting may be manufactured of a plastic or rubber product and be colored in so that organic matter wash up on it would not show up as readily.
[0102] As previously suggested the environment resistant retaining wall block is utilized in the construction of any type of wall or border. In application, a foundation is first created in the area that the wall or border is to be constructed. The foundation preferably is flat and or level, firmly packed to reduce settling and can accommodate one or more retaining blocks 10 . Once a foundation is completed, a first row is laid by filling each individual retaining block 10 with a fill material and placing each individual or multi-unit block, side by side until the row is completed. It is noted that individual rows or partial rows of blocks may be placed into position and then filled to create ease in wall construction. Such action would allow for filling of the block during the backfilling behind the block. The filling of the retaining wall block gives it the added weight that it needs to retain its structure and hold it in place. A funneling device may be utilized, which fits securely into the openings or apertures of the retaining wall block to guide fill into the chamber of the block. The first row may be straight or rounded. An example of a rounded first row is depicted in FIG. 17 . Upon completion of the first row, additional rows are constructed by performing the same filling process and placing the retaining wall block 10 in the proper position until a continuous retaining wall is completed. Generally, a continuous retaining wall may include stacked rows wherein individual retaining blocks are placed adjacently to one another thereby eliminating or minimizing cracks or gaps in the wall. Retaining wall blocks 10 may be positioned directly over other retaining wall blocks 10 in lower rows or may be staggered. It is noted that each retaining wall block placed in the retaining wall may be configured to retain and seal the contents of the fill material. This is accomplished by either one or more plugs or covers that seals each open aperture or by enclosing or covering an open aperture with a portion of an adjacent block. Furthermore, the retaining wall blocks 10 of the upper rows may overlap the back of retaining wall blocks 10 of lower rows if a retaining flange 24 is included on the block or in some embodiments when the blocks include anchoring devices. In the alternative or additionally, each individual retaining block 10 may be locked into position with adjacent blocks if pegs 24 and apertures 22 or clips 94 are present on the retaining block 10 .
[0103] Upon completion of the top row of the retaining wall, a cover or capping block 98 may be placed over the top row to close the apertures 22 of the top panels 12 or to provide a finishing border to the top of the retaining wall. An example of a capping block 98 , as depicted in FIG. 20 , may be polygonal in shape and include textured faces on both the front panels 80 and back panels 100 of the block 98 . The capping blocks 98 may further include pegs (not shown), similar to those depicted in the previous block embodiments, that may be utilized to secure the capping block to the blocks positioned below. Alternatively, the capping blocks may be secured to the blocks below by any means known in the art, such as clips, tacks, adhesives or the like. The capping blocks may be filled with a fill material, similar to the other embodiments of the present invention, or may be a simple thinner block that may include a plurality of reinforcing partitions 72 as disclosed in FIG. 20 .
[0104] Embodiments of the present invention may also be used in conjunction with regular dry cement process blocks, bricks or stones, such as those produced by Keystone(& or Anchorg Wall Systems. A retaining wall constructed in water or along a waterfront property may utilize the retaining wall block of the present invention at water level and below and then the regular keystone or retaining wall materials can be used on top of the retaining wall block of the present invention. The utilization of the retaining wall block of the present invention would be easy to match colors with the conventional retaining wall building materials because the materials utilized to manufacture the present invention can be colored and designed to match virtually any type of retaining wall construction material.
[0105] Furthermore, the retaining wall block may be manufactured in a multitude of different sizes, shapes and configurations. For example, an embankment or steep shoreline could support a retaining wall configured in a step like arrangement or design. Such a structure, may be utilized as a retaining wall and/or a stairway down to the beach or to the water.
[0106] While the invention has been illustrated and described in detail in the drawings and foregoing description, such an illustration and description is to be considered as exemplary and not restrictive in character, it being understood that only the preferred embodiments have been shown and described and that all changes and modifications that come within the spirit of the invention are desired to be protected. | The present invention relates to a retaining wall block that is resistant to damage and wear caused by the environment it is placed into. The deterioration resistant block is generally a hollowed frame or shell of a deterioration resistant material that is lightweight and is configured to accept and retain any type of filling material. The filling material provides weight and stability to the retaining wall block and also provides weight, stability and security to a retaining wall constructed of such blocks. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to Canadian Patent Application 2,647,900 filed Dec. 23, 2008 and claims the benefit of U.S. Provisional Patent Application Ser. No. 61/193,799 filed Dec. 23, 2008, the entire contents of both of which are herein incorporated by reference.
FIELD OF THE INVENTION
[0002] The present application is related to inhibitors of a 9-cis-epoxycarotenoid dioxygenase (NCED), particularly for use in regulating abscisic acid (ABA) biosynthesis in plants and seeds.
BACKGROUND OF THE INVENTION
[0003] Abscisic acid (1, ABA) is a plant hormone involved in the regulation of important developmental functions including seed maturation, desiccation tolerance and dormancy, as well as adaptation to environmental stress through stomatal closure and modification of gene expression. 1-3 The biosynthesis of ABA 1 begins with isopentenyl diphosphate which enters the mevalonic acid-independent 2-C-methyl-d-erythritol-4-phosphate pathway producing plastidic isoprenoids, including carotenoids. 4 Enzymatic cleavage of C 40 carotenoid cis-xanthophylls (neoxanthin 2 and violaxanthin 3) at the 11′-12′ double bond by a 9-cis-epoxycarotenoid dioxygenase (NCED) produces C 15 (xanthoxin 4) and C 25 metabolites and represents the first committed step in ABA biosynthesis ( FIG. 1 ). Xanthoxin 4 is subsequently converted by an alcohol dehydrogenase (ABA2) into abscisyl aldehyde 5, which is oxidized to ABA 1 by an abscisic aldehyde oxidase (AAO3). 3 The catabolism of ABA occurs principally through oxidation of one of the methyl groups of the ring (8′-carbon atom, using convention for ABA numbering) mediated by members of a class of P450 monooxygenase enzymes, CYP 707A. 5 The catabolite phaseic acid (6, PA) which occurs as the result of reversible cyclization of 8′-hydroxyABA, is reduced by an unknown reductase to afford dihydrophaseic acid (7, DPA). ABA can also be metabolized to the glucose conjugate 8. 3
[0004] First identified in maize (VP14), NCEDs have also been found in a variety of other species including Arabidopsis thaliana (AtNCED3), bean (PvNCED1), tomato (LeNCED1), avocado (PaNCED1 and PaNCED3) and cowpea (VuNCED1). 6-11 AtNCED3 is a member of the carotenoid cleavage enzyme family of Arabidopsis thaliana , which consists of nine enzymes. 12 In general, the family is characterized by a plastid-targeting transit peptide, an amphipathic α-helix domain and a catalytic domain which contains four conserved histidine residues responsible for non-heme iron co-ordination. AtNCED3 is found in both the stroma and bound to the thylakoid membrane, accounts for NCED activity in roots, contributes to NCED activity in developing seeds and is the major stress-induced NCED in leaves of Arabidopsis thaliana. 12 Recently, immunohistochemical analysis revealed that the AtNCED3 protein is detected exclusively in the vascular parenchyma cells of water-stressed plants. 13 Due to ABA's important role in plant physiology, significant effort has been expended on investigating functional aspects of ABA 1 biosynthesis, regulation and action. ABA-deficient mutants are powerful tools for elucidating ABA's role in planta, as are chemical inhibitors of ABA 1 biosynthesis which have broad applicability to many plant species.
[0005] General carotenoid biosynthesis inhibitors such as fluridone, a potent broad spectrum herbicide that inhibit phytoene desaturase in the carotenoid biosynthesis pathway, have been used to inhibit ABA 1 biosynthesis. 14,15 While fluridone does inhibit ABA 1 biosynthesis, a corresponding general repression of the carotenoid biosynthesis pathway limits its application for biochemical investigations including those of carotenoid cleavage enzymes and products. To address this problem, Abamine compounds 9 and 10 were developed as inhibitors of NCED's, based on early observations that a number of inhibitors of soybean lipoxygenase were effective in reducing ABA accumulation in stressed soybean cell cultures and seedlings. 16 One of the active compounds, nordihydroguaiaretic acid, served as the starting structure for generation of analogs with improved NCED inhibitory activity, leading to development of the tertiary amines Abamine (9, ABM) and Abamine SG (10, ABM-SG) (FIG. 2 ). 17,18 Arabidopsis plants treated with ABM 9 showed a significant decrease in drought tolerance and under simulated osmotic stress ABM 9 inhibited stomatal closure in spinach leaves. The latter effect was counteracted by co-application of ABA 1. ABM-SG 10 strongly inhibited the expression of ABA-responsive and catabolic genes in plants under osmotic stress. Finally, both ABM 9 and ABM-SG 10 reduced ABA metabolite accumulation by 35% and 77% respectively and were shown to act as competitive inhibitors of the cowpea NCED enzyme, with Ki's of 18.5 μM and 38.8 μM respectively.
[0006] There remains a need for NCED inhibitors for use in regulating ABA biosynthesis in plants.
SUMMARY OF THE INVENTION
[0007] There is provided a compound of formula (I):
[0000]
[0000] wherein:
[0008] R 1 is —SR 10 , —O—C(O)—R 11 , —NR 12 R 13 , where R 10 is a C 1-8 -alkyl group or a phenyl group unsubstituted or substituted by a C 1-4 -alkyl group, R 11 is a thiophenenyl, furanyl or pyrrolyl group, R 12 is H or a C 1-4 -alkyl group and R 13 is a C 1-8 -alkyl group or a phenyl group unsubstituted or substituted by a C 1-4 -alkyl group;
[0009] R 2 is H or a C 1-4 -alkyl group;
[0010] R 3 and R 4 are independently H or C 1-4 -alkyl groups;
[0011] R 5 and R 6 are independently H, OH or OR 14 , or taken together are ═O, where R 14 is a protecting group;
[0012] R 7 is H or a C 1-4 -alkyl group;
[0013] R 8 is H, R 9 is OH and R 15 is H, or R 15 is H and R 8 and R 9 taken together are —O—, or R 9 is OH and R 8 and R 15 taken together form a bond; and,
[0014] R 18 and R 19 are both H, or R 18 and R 19 taken together form a bond,
[0000] or a plant physiologically acceptable salt thereof.
[0015] Preferably, R 10 is ethyl or phenyl. Preferably, R 11 is thiophenenyl. Preferably, R 12 is H. Preferably, R 13 is phenyl. Preferably, R 1 is —SR 10 . Preferably, R 2 is methyl. Preferably, R 3 is methyl. Preferably R 4 is methyl. Preferably, one of R 5 and R 6 is OH or R 5 and R 6 taken together are ═O. Preferably, R 7 is methyl. Preferably, R 15 is H. Preferably, R 18 and R 19 taken together form a bond.
[0016] Plant physiologically acceptable salts are generally known in the art and include, for example, acetates, hydrochlorides, sulfates.
[0017] Compounds of the present invention may be synthesized in accordance with a process as illustrated in Scheme 1:
[0000]
[0018] wherein R 1 , R 2 , R 3 , R 4 , R 5 , R 6 , R 7 , R 8 and R 9 are as defined above; and R 16 is OH and R 17 is H, or R 16 and R 17 taken together are ═O.
[0019] Referring to Scheme 1, in Step 1 allylic compounds (III) where R 9 is OH may be prepared from 4-oxoisophorones (II) by initial reduction of (II) followed by conversion of the resulting 1,4-diones to allylic alcohols (III) by known methods. 20 Reduction may be accomplished by any suitable means, for example by Baker's yeast reduction or with an appropriate reducing metal (e.g. zinc in acetic acid). Alternatively, allylic compounds (III) where R 8 and R 9 taken together are —O— may be prepared from 4-oxoisophorones (II) by an initial multi-step synthesis (Step 1A 22 ) to yield allylic epoxide (IV) followed by conversion of (IV) to (III) (Step 1B) by condensing (IV) with a 3-iodobut-2-en-1-ol. The condensation of (IV) with 3-iodobut-2-en-1-ol is preferably performed in the presence of a catalyst. Compounds of formula (III) where R 16 is OH and R 17 is H may be converted to compounds of formula (III) where R 16 and R 17 taken together are ═O by oxidation, for example with MnO 2 . The protecting group, R 14 , may be any suitable protecting group known in the art, for example, t-butyldimethylsilyl (TBDMS) or t-butyldiphenylsilyl (TBDPS).
[0020] Conversion of (III) to (Ia) (Step 2A), where (Ia) represents a sub-set of compounds of formula (I), may be accomplished by condensing (III) with R 1 L, where L is a leaving group. This condensation is preferably performed in the presence of a base (e.g. tributylphosphine, triethylamine) when R 16 is OH, or with subsequent action of a reducing agent (e.g. sodium borohydride) when R 16 and R 17 taken together are ═O. The leaving group may be, for example, H, halogen (e.g. Cl, Br), tosylate, brosylate or a second unit of R 1 .
[0021] Compounds (Ib), another sub-set of compounds of formula (I) where the allylic bond has been hydrogenated to an olefinic bond, may be formed from (II) (Step 1C and Step 2B). Thus, (II) may be converted to (V) in Step 1C by known methods 20 as indicated above for Steps 1 and 2A without the initial reduction of (II) to the 1,4-dione, followed by reduction of the allylic bond to an olefinic bond in Step 2B using H 2 and an appropriate catalyst (e.g. Pd, Pd—CAaCO 3 —PbO) or by using diisobutlyaluminum hydride.
[0022] If required or desired, deprotection to yield the corresponding hydroxy may be accomplished by generally known methods, for example by the action of tetra-n-butylammonium fluoride (TBAF). Compounds may be converted to salts by reaction with a suitable acid or base.
[0023] Compounds and salts thereof of the present invention are useful for inhibiting 9-cis-epoxycarotenoid dioxygenase (NCED) in plants. In particular, they are useful for regulating abscisic acid (ABA) biosynthesis in plants. More particularly, they are useful for regulating seed maturation, desiccation tolerance, dormancy and adaptation to environmental stress through stomatal closure and modification of gene expression in plants. Environmental stress includes abiotic stress (e.g. heat, cold, alkalinity, acidity) and biotic stress (e.g. pathogens).
[0024] Thus, in one embodiment of the present invention, there is provided a method of inhibiting 9-cis-epoxycarotenoid dioxygenase (NCED) in a plant or seed comprising administering to the plant or seed a 9-cis-epoxycarotenoid dioxygenase inhibiting effective amount of a compound of formula (I) or a plant physiologically acceptable salt thereof. The method preferably comprises identifying whether the plant is in need of 9-cis-epoxycarotenoid dioxygenase (NCED) inhibition.
[0025] Compounds or salts thereof of the present invention may be applied directly to plants or seeds or formulated into compositions for administration to plants or seeds. Compositions may comprise, for example, common plant physiologically acceptable carriers, excipients, diluents and/or nutrients, for example, water, buffers, sugars, salts, vitamins, etc. Advantageously, the compounds or salts thereof may be administered to the plants or seeds by inclusion in a growth medium on which the plant or seed grows, or by spraying the plants or seeds with the compound, a salt thereof or a composition thereof. The compounds or salts thereof may be administered in a suitably effective amount to inhibit NCED. Concentrations of 0.25 μM or more in the application medium are generally suitable. Compounds, salts thereof or compositions thereof may be packaged into a commercial package together with instructions for use.
[0026] Further features of the invention will be described or will become apparent in the course of the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] In order that the invention may be more clearly understood, embodiments thereof will now be described in detail by way of example, with reference to the accompanying drawings, in which:
[0028] FIG. 1 . ABA biosynthesis and catabolism pathway of higher plants from the committed step of C 40 -carotenoid cleavage of either 9-cis-neoxanthin 2 or 9-cis-violaxanthin 3 by AtNCED3.
[0029] FIG. 2 . Structures of AtNCED3 SLCCD inhibitors.
[0030] FIG. 3 . Synthesis of AtNCED3 SLCCD inhibitors. a) See reference 20 ; b) n-Bu 3 P, (C 2 H 5 S) 2 ; c) TBAF, THF; d) See reference 22 e) (Z)-3-iodobut-2-en-1-ol, (Ph 3 P) 4 Pd, CuI, (i-Pr) 2 NH; f) n-Bu 3 P, (C 6 H 5 S) 2 ; g) MnO 2 ; h) C 6 H 5 NH 2 , Δ; i) NaBH 4 .
[0031] FIG. 4 . Kinetic analysis of recombinant purified AtNCED3 activity. Michaelis-Menton plot for cleavage of 9-cis-neoxanthin 2 by recombinant AtNCED3 indicating a K m of 24 μM.
[0032] FIG. 5 . Relative inhibition of recombinant AtNCED3 activity by various SLCCD compounds at 1 mM concentration.
[0033] FIG. 6 . Computational docking of compounds to the AtNCED3 homology model. Docking was performed using the Autodock v3.1 software. 38 Conserved histidine residues are shown coordinating the iron (orange). The active site water (light blue) is shown in relation to the docked molecules. Molecules include (A) 9-cis-neoxanthin 2, (B) compound 17 and (C) compound 12. Sulfur heteroatoms in the two SLCCD compounds are highlighted in yellow.
[0034] FIG. 7 . Total ABA metabolite levels in mannitol stressed Arabidopsis thaliana plants treated with SLCCD inhibitors. Plants were treated with 33 μM inhibitors (compounds 13 (inverted closed triangles), 17 (closed circles), 18 (open circles) and ABM 9 (open triangles)) for 2 hours prior to being stressed with mannitol. Plants were harvested 6 hours after the inhibitor treatment and compared to plants that were mannitol stressed only (open squares), or non-treated/non-stressed plants (closed squares). Metabolites quantified and summed at each time point include abscisic acid-glucose ester, dihydrophaseic acid, phaseic acid and abscisic acid.
[0035] FIG. 8 . Germination of Arabidopsis thaliana plants in the presence of each of SLCCD inhibitor compounds 18 (inverted closed triangles), 13 (closed circles), 17 (open circles), (+)-ABA 1 (open triangles), and germination of plants on media without added compounds (closed square).
[0036] FIG. 9 . Target gene transcript levels in mannitol stressed Arabidopsis thaliana plants treated with SLCCD inhibitors. A) Effect of compound 13. Plants were treated with 10 or 33 μM compound 13 for 2 hours prior to being stressed with mannitol. Plants were harvested 6 hours after the SLCCD compound treatment and compared to mannitol stressed only plants or non-treated/non-stressed plants. Target genes included Rd29B, CYP707A1 and CYP707A3. Transcript levels were normalized against the UBQ10 gene. B) Effects of SLCCD compounds on AtNCED3 expression. Experiments were carried out as described for A, but with each of SLCCD compounds 13, 17 and 18.
[0037] FIG. 10 . HPLC profiles showing substrate (left panel) and product (right panel) for AtNCED3 in vitro reactions. The substrate 9-cis-neoxanthin peak is observed at 14.187 minutes with three maxima at 415, 438 and 467 nm and the C 25 -allenic apo-aldehyde cleavage product observed at 11.593 minutes with a maxima of 423 nm.
[0038] FIG. 11 . Inhibition kinetic Dixon plot analyses of recombinant AtNCED3 activity measured in the presence of 50 μM (diamonds), 30 μM (squares) and 10 μM (triangles) 9-cis-neoxanthin, with compounds 9, 10, 13, 17 and 18 at the indicated concentrations. K i values are reported in Table 1.
[0039] FIG. 12 . Computational docking of compounds to the AtNCED3 homology model. Molecules include (A) 3-ON, (B) xanthoxin, (C) compound 18. Conserved histidine residues are shown coordinating the iron (orange). The active site water (light blue) is shown in relation to the docked molecules.
[0040] FIG. 13 . Profiling of ABA and individual catabolites in plants treated with 33 μM of the indicated SLCCD compounds. Plants were treated with compounds for two hours prior to mannitol stress (MS) treatment. Time points (6, 24 and 48 hours) indicate samplings taken in hours following the initial compound treatment. Values are compared to those obtained from plants treated with mannitol only or non-treated/non-stressed plants. Metabolites quantified include abscisic acid (ABA, 1), abscisic acid-glucose ester (ABAGE, 8), dihydrophaseic acid (DPA, 7) and phaseic acid (PA, 6) as indicated in related plots.
[0041] FIG. 14 . Profiling of individual gene transcripts in plants treated with 10 or 33 μM compound 13 for two hours prior to mannitol stress (MS) treatment. Time points indicate samplings taken in hours following the initial compound treatment. Values are compared to those obtained from plants treated with mannitol only or non-treated/non-stressed plants. Quantified gene transcripts include, Rd29B, CYP707A1 and CYP707A3.
[0042] FIG. 15 . Profiling of AtNCED3 gene transcription in plants treated with 10 and 33 μM of one of compounds 13, 17 or 18 for two hours prior to mannitol stress treatment (MS). Time points indicate samplings taken in hours following the initial compound treatment. Values are compared to those obtained from plants treated with mannitol only or non-treated/non-stressed plants.
DESCRIPTION OF PREFERRED EMBODIMENTS
[0043] In preferred embodiments, the design, synthesis and characterization of novel sesquiterpene-like carotenoid cleavage dioxygenase (SLCCD) inhibitors 11-18 ( FIG. 2 ) are described below. These novel compounds were designed starting with the sesquiterpenoid subunit of the substrate and product of the NCED enzyme. Of these inhibitors, three were found to inhibit recombinant AtNCED3 activity more strongly. These have been fully characterized in vitro, with kinetic inhibition constants comparing favorably to those of the ABM-type compounds. Computational docking of the inhibitors correlated with these findings and supported the proposed functional mechanism. In vivo, one inhibitor in particular, SLCCD inhibitor compound 13 was found to moderate ABA responsive genes and ABA metabolism. Interestingly, the inhibitors reduced expression of AtNCED3, presenting a second mechanism for inhibition of ABA 1 biosynthesis by the molecules.
[0044] While in vitro studies identified SLCCD compound 17 as the most promising candidate inhibitor, hormone profiling data convincingly demonstrated that SLCCD 13, a more easily synthesized racemic compound, best met the objective of reducing the total ABA metabolite levels in planta. Overall, these sesquiterpenoid-like inhibitors present new tools for controlling and investigating ABA biosynthesis, regulation and effects.
Methods:
AtNCED In Vitro Assay Substrate Preparation
[0045] Fresh spinach was macerated under liquid nitrogen and extracted five times with three volumes of methanol/0.1% KOH. Samples were dried using a roto-evaporator, resuspended in acetone and then chilled on ice for one hour. The solvent was subsequently transferred to a new flask, roto-evaporated and resuspended in acetonitrile/acetone (1:1) mixture. The mixture was applied to a gravity flow column containing C-18 silica gel (Sigma) equilibrated in 65% acetonitrile/35% water (solvent C). The column was washed with 49% acetone (solvent D)/51% solvent A and 20 mL of 55% solvent D/45% solvent A while collecting 5 mL fractions. Fractions containing neoxanthin were pooled, dried, and resuspended in 100 μL of methanol. The pooled mixture was separated using an Agilent 1100 series HPLC and a Supelcosil™ LC-18 (25 cm×10 mm, 5 m) (Supelco) column equilibrated with solvent A. The HPLC method consisted of a linear gradient over 30 minutes from 100% solvent A to 100% solvent D with a flow rate of 4 mL/minute at 22° C. and monitored with a PDA detector at 436 nm. The neoxanthin fractions were collected, dried and resuspended in ethanol. Neoxanthin was quantified by determining its OD439 using a PerkinElmer Lambda 35 UV/VIS Spectrometer and applying its extinction coefficient of 2243 (A 1% 1cm ). 30
Recombinant AtNCED3 Expression, Purification and In Vitro Assays
[0046] AtNCED3 was over-expressed using the pRL296 expression vector (a gift from M. Cygler, BRI, Montreal) in E. coli (BL21)DE3 cells as a glutathione-S-transferase fusion protein and affinity purified using glutathione sepharose 4 fast flow resin (GE Healthcare) as described previously. 35 Essentially, cells were grown to an OD600 of 0.45 at 37° C. and 200 rpm shaking. The culture was induced with 1 mM isopropyl-β-d-thiogalactoside for 16 h at 15° C. and 200 rpm shaking. The cells were pelleted and resuspended in 50 mM Tris-HCl (pH 8.0) 1 mM DTT and 0.5% protease inhibitor cocktail set III (CalBiochem). Cells were lysed using a french press at 20,000 psi and affinity purified as per manufacturer's instructions (GE Healthcare). Protein concentration was determined by the method of Bradford. 36
[0047] Enzymatic assays contained 100 mM Bis-Tris (pH 6.7), 5 M FeSO 4 , 10 mM ascorbate, 0.05% Triton™ X-100, catalase (1 mg/mL), neoxanthin and inhibitor to a total volume of 5 L of ethanol and 8 g AtNCED3 to a total assay volume of 100 L. Assays were incubated at 22° C. for 20 min. The assays were stopped with the addition of 50 L of 25% Triton™ X-100 and extracted with 150 L of ethyl acetate. All procedures were performed under red-light to minimize photo-induced damage to assay components and products. 6 Fine chemicals and solvents were purchased from Sigma-Aldrich. 75 μL of the assay extract was injected into an Agilent 1100 series HPLC machine equipped with a Supelcosil™ LC-18 (3.3 cm×4.6 mm, 3 m) (Supelco) column pre-equilibrated with 15% acetonitrile (solvent B)/85% water (solvent A). Solvent B increased to 35% over ten minutes, followed by a linear gradient of 65% solvent B to 100% solvent D over 10 minutes. Solvent D was maintained at 100% for 2 minutes and then the column was returned to 15% solvent B for 5 min. The flow rate was maintained at 1.5 mL/min. and monitored with a photodiode array (PDA) detector at 436 and 262 nm.
[0048] Evaluation of recombinant AtNCED3 kinetic parameters for K m was accomplished using Michaelis-Menten equation plotted with EnzFitter™ v2.0.18.0 (Biosoft). The K i for inhibitors was determined using a Dixon plot and concentration ranges of 250, 200, 150, 100, 50 and 0 μM inhibitor in the presence of either 55, 30 or 10 μM 9-cis-neoxanthin 2. 5
Homology Modeling of AtNCED3
[0049] A homology model of AtNCED3 was built using the X-ray crystal structure of Synechocystis sp. PCC 6803 ACO (pdb code: 2biw; available at the RCSB Protein Data Bank) at 2.39 Å resolution as a structural template. 25 To model AtNCED3, amino acid alignments were made between ACO, AtNCED3 and VP14. AtNCED3 shares 25% and 45% amino acid identity and similarity with ACO, and 64% and 76% respectively with VP14. 37 Highly conserved amino acids including H183, H238, H304 and H484 forming the octahedral coordination of the non-heme iron required for catalysis of the dioxygenase reaction were used to aid in development of a suitable alignment and ultimately build the homology model. Homology modeling jobs were submitted to the Swiss-Model servers using the DeepView program as an interface. 26 Each generation of the AtNCED3 homology model was energy minimized within DeepView using 1000 steps of steepest descent followed by 1000 steps of conjugate gradient minimization until the RMS gradient of the potential energy was less than 0.01 kJ.
In Silico Docking of AtNCED3 Active Site SLCCD Inhibitor Interactions
[0050] Inhibitor structures were created using CS ChemOffice™ v9 (CambridgeSoft). In silico docking of inhibitor structures to the AtNCED3 homology model were performed using AutoDock™ v3.1 on a Silicon Graphics Octane2 Workstation. 38 Inhibitor structures were docked within a grid box encompassing the entire catalytic pocket of AtNCED3 corresponding to 80×36×30 points using a spacing of 0.375 Å between grid points. The docking parameters consisted of 20 Lamarckian Genetic Algorithm runs using a population size of 100 individuals and 1,000,000 energy evaluations. Final docked structures having orientations less than or equal to 0.5 Å root mean square deviation were clustered.
[0000] In Vivo Application of SLCCD Inhibitors to Arabidopsis thaliana Col-0
[0051] For each condition to be tested, three hundred wild-type Arabidopsis thaliana Col-0 seeds (LEHLE) were sterilized, vernalized and sewn onto 200 mL of Sunshine Mix #3 (Sun Gro) potting material in an 8×8×4 cm pot. Plants were watered continuously with 25 g/100 mL of 20-20-20 (PlantProd™) fertilizer and grown at 22° C. with a 16 hour photoperiod for 22 days. Plants were pre-treated with 50 mL/pot of Buffer A (10 mM HEPES pH 6.5) (Sigma)+/−10 or 33 μM test compound for 2 hours. Plants were then soaked with 50 mL/pot of Buffer A containing 0.4 M mannitol (Sigma)+/−10 or 33 μM test compound. Non-treated/non-stressed control plants were simply soaked in Buffer A at the designated time points. Aerial plant tissue was harvested after 6, 12 and 48 hours from the time of initial inhibitor treatment and flash frozen in liquid nitrogen. Half of the tissue samples were lyophilized for metabolite profiling and the other half taken for quantitative reverse-transcription polymerase chain reaction (qRT-PCR) analysis.
[0000] Metabolite Profiling of Arabidopsis thaliana Hormone Levels
[0052] Freeze-dried tissue was homogenized using a multi-tube ball mill (Mini-BeadBeater-96™, Biospec Products Inc., Bartlesville, Okla., USA) and 50 mg of each sample was weighed out into individual Falcon tubes. To each sample, 100 μL of a cocktail of internal standards comprised of (−)-5,8′,8′,8′-d4-ABA, (−)-7′,7′,7′-d3-PA, (−)-5,8′,8′,8′-d4-7′OH ABA, (−)-7′,7′,7′-d3-DPA and (+)-4,5,8′,8′,8′-d5-ABAGE, each at a concentration of 0.2 ng/μL and dissolved in a mixture of water:acetonitrile (1:1, v/v) with 0.5% glacial acetic acid, was added. Further, 3 mL of isopropanol:water:glacial acetic acid (80:19:1, v/v/v) extraction solvent was added, and samples were placed in the fridge (4° C., in the dark) on an orbital shaker at about 350 rpm. After 18-24 hours, the samples were centrifuged at 4.4 krpm for 10 min, the supernatant was transferred to a disposable culture tube, and a second portion of 500 μL extraction solvent mixture was added to wash the pellet. After vortexing and centrifuging again at 4.4 krpm for 10 min, each wash was combined with its appropriate supernatant. The organic extract was dried under reduced pressure, then re-dissolved in 100 μL methanol:glacial acetic acid (99:1, v/v) followed by 900 μL of aqueous 1% glacial acetic acid. This mixture was extracted with 2 mL hexane, and then the aqueous layer was dried down under reduced pressure. The sample was further reconstituted in 2 mL aqueous 1% glacial acetic acid and loaded onto an Oasis MCX SPE cartridge (3 cc, Waters Corporation, Mississauga, Ontario, Canada). After a wash with 3 mL aqueous 1% glacial acetic acid, samples were eluted with 1 mL methanol:glacial acetic acid (99:1, v/v) and then dried down under reduced pressure. The extract was re-dissolved in 100 μL methanol:glacial acetic acid (99:1, v/v) followed by 900 μL of aqueous 1% glacial acetic acid. This mixture was further cleaned on an Oasis HLB SPE cartridge (1 cc, Waters Corporation, Mississauga, Ontario, Canada). After a wash with 1 mL aqueous 1% glacial acetic acid, the fraction containing ABA and ABA metabolites was eluted with 1 mL acetonitrile:water:glacial acetic acid (30:69:1, v/v/v) and then was evaporated to dryness. The final residue was dissolved in 200 μL of acetonitrile:water (15:85, v/v) containing 0.1% glacial acetic acid and 100 pg/μL (±)-3′,5′,5′,7′,7′,7′-d6-ABA as a recovery standard. Finally, the sample was subjected to LC-ES-MS/MS analysis and quantification, as described in Owen and Abrams, 2008. 39
Seed Germination Assay
[0053] Arabidopsis thaliana Col-0 seeds were sterilized by washing them with 10% sodium hypochlorite and 20% sodium dodecyl sulfate (Sigma) for five minutes and then rinsing four times with sterile water. Seeds were moist chilled for 4 days and then plated on germination medium (0.41% MS salts, 1% sucrose, 0.05% MES and 0.1% Gamborg's vitamins, pH 5.7, 0.7% agar) (Sigma) containing either 0.1, 0.33, 1.0 or 3.33 μM of inhibitor or (+)-ABA 1. As a control, seeds were sewn and germinated on media only without inhibitors or (+)-ABA 1. Germination was recorded over seven days and indexes calculated as described previously. 40
[0000] Quantitative Reverse-Transcription PCR (qRT-PCR)
[0054] 250 mg of frozen plant material was ground under liquid nitrogen and extracted for mRNA as suggested by the manufacturer (PolyATract™ System 1000, Promega). The resulting mRNA was quantified and checked for quality using a Nano-Drop™ ND-1000 Spectrophotometer. QuantiTect™ Reverse Transcription Kit (Qiagen) was used to produce cDNA as directed by the manufacturer from 20 ng of starting mRNA. Quantitative PCR was performed on 1 μL of cDNA product using a Bio-Rad iCycler™ and the QuantiTect™ SYBR Green PCR Kit (Qiagen) coupled with QuantiTect™ Primer Assays (Qiagen) for the gene targets; AtNCED3 (NM — 112304), Rd29B (NM — 124609), CYP707A1 (NM — 118043), CYP707A3 (NM — 123902) and UBQ10 (NM — 178968). The pre-validated primer sets are as follows indicated by the GeneGlobe (www1.qiagen.com/GeneGlobe/default.aspx) product name and (catalogue number): At_NCED3 — 1_SG (QT00769573), At_RD29B — 1_SG (QT00840399), At_CYP707A1 — 1_SG (QT00808339), At_CYP707A3 — 1_SG (QT00739242), At_UBQ10_va.1_SG (QT01123745). Relative changes in transcript level were normalized using UBQ10 and quantified as previously described. 41
Results:
Design and Synthesis of the SLCCD Inhibitors
[0055] The present compounds were designed to incorporate the 9-cis double bond geometry of the substrates and product of AtNCED3 as well as a heteroatom at carbon 12 (carotenoid numbering) of the inhibitor molecules. All of the SLCCD inhibitors 11-18 were synthesized from 4-oxoisophorone 19 ( FIG. 3 ). Bakers' yeast reduction of 19 afforded (−)-(R)-2,2,6-trimethylcyclohexa-1,4-dione 19 which was converted into chiral nonracemic allylic alcohols 20, 21, 23 and 24. 20 Racemic allylic alcohol 22 was prepared in a similar manner, except that reduction of 19 was accomplished using zinc in acetic acid. 21 The terminal allylic alcohols were then converted to the corresponding ethyl sulfides by reaction with ethyl disulfide in the presence of tributylphosphine. 22 Inhibitor 16 was obtained by reacting 2-thiopheneacetyl chloride and allylic alcohol 22 (protected as the neopentylglycol ketal). The xanthoxin-like allylic alcohol 22 was prepared through a Sonogashira coupling between the terminal acetylene in 21 23 and (Z)-3-iodobut-2-en-1-ol. Alcohol 22 was then converted to the phenyl sulfide 13 with 54% yield. The nitrogen-containing inhibitor 18 was synthesized by oxidation of allylic alcohol 22 with MnO 2 , followed by imine formation using phenyl amine and then reduction to the amine.
In Vitro Assays and Kinetic Analyses
[0056] Recombinant AtNCED3 including a C-terminally located glutathione-S transferase fusion tag was expressed in E. coli and purified by affinity chromatography. In vitro assays demonstrated the functionality of the recombinant purified enzyme product. Sample HPLC profiles ( FIG. 10 ) show cleavage of the 9′-cis-neoxanthin 2 substrate (R t 14.2 min. with three maxima at 415, 438 and 467 nm) producing the expected C 25 -allenic apo-aldehyde cleavage product (R t 11.6 min. with a maxima of 423 nm). Further kinetic analysis fitted by non-linear regression analysis defined a K m of 24 μM ( FIG. 4 ). This value correlates well with the K m 's of 27 μM and 49.0 μM determined previously for VP14 and VuNCED1. 18,24
[0057] Using this recombinant enzyme and assay system, the eight potential inhibitor compounds were tested for their relative ability to inhibit AtNCED3 activity at 1 mM concentration ( FIG. 5 ). Compounds 12, 17 and 18 completely inhibited AtNCED3 activity at 1 mM, while 13 inhibited AtNCED3 activity by 75%. Compound 12 is one of the stereoisomers of racemic 13. The latter being easier to synthesize (and thus of higher potential practical application), it was decided to move forward with compounds 13, 17 and 18 for detailed in vitro and in vivo testing. Dixon plots indicated that compounds 13, 17 and 18 competitively inhibit recombinant AtNCED3 with K i 's comparable or better than those observed for ABM and ABM-SG (Table 1 and FIG. 11 ).
[0000]
TABLE 1
Compound
K i (μM)
K m (μM)
2 (9-cis-Neoxanthin)
—
24
13
93
—
17
57
—
18
87
—
10 (ABM-SG)
86
—
9 (ABM
132
—
Homology Modeling and SLCCD Inhibitor Docking
[0058] Recently a crystal structure was determined for Synechocystis apocarotenoid-15,15′-oxygenase (ACO), a fungal homologue of the NCEDs. 25 AtNCED3 shares 25% identity and 45% similarity with ACO at the amino acid level. Homology modeling using the Swiss-Model servers generated a hypothetical protein structure of AtNCED3 which maintained the octahedral coordination of the four active site histidines at 2.14, 2.05, 2.16 and 2.31 Å from the iron atom for H164, H211, H276 and H450 respectively. 26 Structural differences between the AtNCED3 model and ACO were limited to small surface exposed loops related to a few minor alignment gaps. As controls to test the AtNCED3 model, 9-cis-neoxanthin 2, the substrate of ACO (all-trans-(3R)-hydroxy-8′-apo-β-carotenol (3-ON)), and xanthoxin 4 structures were docked ( FIGS. 6A , 12 A and 12 B). The 3-ON molecule docked to the AtNCED3 model with a similar orientation as observed in the ACO crystal with its β-ionone ring oriented towards the tunnel entrance but shifted in toward the catalytic site by 5 Å. This positions the C12 and C13 bond within 3.95 Å of the iron atom and 2.10 Å of a coordinated active site water molecule. Docking of 9-cis-neoxanthin 2 resulted in the epoxide ring entering the protein channel first, yielding a final orientation with the C11-C12 bond 4.4 Å away from and directly over the iron atom and 2.3 Å away from the active site water molecule. The xanthoxin molecule docked in the opposite orientation from the 9-cis-neoxanthin substrate, with its epoxide ring towards the tunnel entrance and its C10 carbon atom 3.6 Å and 1.9 Å from the iron atom and water molecule respectively.
[0059] Docking results correlated well with the in vitro enzyme assay data. Structures representing 12 (the more active stereoisomer of the racemic compound 13), 17 and 18 ( FIGS. 6B , 6 C and 12 V, respectively) all docked in the same orientation as xanthoxin, in close proximity to the iron atom in the binding pocket. The nitrogen of 18 docked 2.67 Å away from the iron atom. The sulfur atoms of 12 and 17 docked 2.6 and 2.65 Å away from the iron atom respectively. Other SLCCD inhibitor molecules that performed poorly in the in vitro trials generally were not targeted to the catalytic site of the binding pocket, or in some instances were not targeted to the binding pocket at all during docking.
Effect of SLCCD Inhibitors on ABA Accumulation Under Osmotic Stress
[0060] Arabidopsis thaliana plants were treated with either ABM 9 or the inhibitor compounds 13, 17 and 18, to evaluate their ability to reduce ABA biosynthesis induced by an osmotic stress. Essentially plants were treated +/− inhibitor compound for 2 hours followed by mannitol stress-treatment in the presence of the same compounds. Mannitol stress has been shown to result in loss of turgor with a corresponding increase in ABA levels through the induction of AtNCED3 in Arabidopsis thaliana. 7,27
[0061] As expected, mannitol treatment alone resulted in an elevation of the levels of ABA and catabolites peaking 24 hours after the imposition of treatment, compared to the levels in non-treated/non-stressed plants ( FIG. 7 ). Accumulation of ABA and catabolites dropped off by 48 hours as described previously. 28 Treatment with compound 13 for two hours prior to and then during mannitol stress-treatment resulted in levels of ABA and catabolites remaining comparable to those of the non-treated/non-stressed control plants in the first 6 hours. By 24 hours, the total levels of ABA and catabolites in the compound 13 treated plants increased to only 8211 pmol/g, significantly below those of the mannitol-stressed only plants (15147 pmol/g). Similar treatment of plants with ABM 9 resulted in higher levels of ABA and catabolites at the first time point, with levels remaining constant (and higher than those for treatment with compound 13) over the remaining time course of the experiment. The remaining two inhibitors, 17 and 18, were less effective than 13 in reducing the effect of the osmotic stress on ABA and catabolite pools. Interestingly, the overall effect observed for compound 13 is not represented in individual plots of ABA levels (or any one other catabolite) alone ( FIG. 13 ). It is only when total accumulation of ABA and its catabolites are considered that the overall effect becomes evident.
[0000] Effect of SLCCD Inhibitors on Arabidopsis thaliana Seed Germination
[0062] Seed germination assays were performed for compounds 13, 17 and 18 to assess the ABA-like character of the inhibitors. 29 Inhibitors had relatively little effect on seed germination at low concentration compared to non-inhibitor treated and ABA treated controls ( FIG. 8 ). At increasing concentrations (0.33 μM) the inhibitors did lead to reductions of seed germination by approximately 15%, compared to 47% for the (+)-ABA 1. Both compounds 13 and 17 reduced seed germination by 26% at 1 μM while 18 showed a more pronounced effect with a 50% reduction compared to 61% for (+)-ABA 1. At the highest concentration tested, compound 13 still only had a modest impact on seed germination at 38% reduction, while compounds 17 and 18 showed 51% and 71% reductions respectively, compared to 96% for (+)-ABA 1.
Effect of SLCCD Inhibitors on Target Gene Transcript Levels Under Osmotic Stress
[0063] In light of the observed effectiveness of compound 13 in moderating ABA and catabolite levels in vivo and its limited effect on seed germination, it was targeted for further evaluation. Specifically, quantitative reverse-transcription PCR was used to assess inhibitor induced changes in gene transcript levels in mannitol stressed plants. The gene targets chosen for this purpose were AtNCED3, the ABA and drought inducible Rd29B and the ABA (inducible) catabolic genes CYP707A1 and CYP707A3. Transcript levels were normalized against UBQ10 mRNA levels. 5,30,31 Mannitol treatment led to the induction of expression of all four target genes within 4 hours of the stress treatment ( FIG. 9 ). Subsequently the mannitol-induced gene transcription levels decrease back to non-treated/non-stressed levels by 24 hours post-treatment and remained low through 48 hours ( FIGS. 14 and 15 ). In general, pretreatment with compound 13 at both 10 and 33 μM concentrations prior to mannitol-stress led to reductions in the accumulation of mRNA transcript levels at 6 hours post-compound treatment for Rd29B, CYP707A1 and CYP707A3 compared to the mannitol-stressed control ( FIG. 9A ). The inhibition of mannitol-induced Rd29b transcription by compound 13 (about 90%) is especially striking and is consistent with the mannitol effect on Rd29b being primarily mediated by ABA. This result indicates the potential of this inhibitor for dissecting the role of ABA in physiological and developmental processes. As observed in mannitol stressed only plants, transcript levels in compound 13 pretreated plants decreased back to non-treated/non-stressed levels by 24 hours and remained low through 48 hours ( FIG. 14 ). In addition to this, compound 13 was also found to decrease the relative expression levels of AtNCED3 in mannitol stressed plants ( FIG. 9B ). While the former results emphasize the lack of ABA-like character for compound 13, the moderation of AtNCED3 transcription represents a useful inhibitor-dependent side-effect that likely further contributes to lowering ABA levels in planta. Testing of compounds 17 and 18 demonstrated similar, although not as pronounced effects on AtNCED3 expression ( FIG. 9B , FIG. 15 ).
Discussion:
Design/Synthesis and Inhibitory Activities of SLCCD Inhibitors
[0064] The design of inhibitors described herein focuses on specific interaction with the non-heme iron atom within AtNCED3, a definitive motif of carotenoid cleavage enzymes. It was envisioned that a molecule maintaining characteristics of the native enzyme substrate 9-cis-neoxanthin 2 or xanthoxin 4 product, but presenting a nitrogen or sulfur heteroatom might specifically occupy the active site of the enzyme with the heteroatom interacting with the non-heme iron, resulting in inactivation of the enzyme. Similar concepts have been applied to inhibitors of other dioxygenase enzymes. 32,33
[0065] In earlier ABA structure activity studies, analogs with the side chain having a triple bond conjugated to a cis double bond were found to be highly active and were also readily synthesized. 20 Therefore the enyne feature was incorporated into the design of the present set of eight potential ABA biosynthesis inhibitors. The epoxy alcohol analogs 17 and 18, which most closely resemble the substrate and product of the NCED, strongly inhibited the NCED enzyme activity in vitro, and demonstrated higher inhibitory function than ABM 9 in this assay. However, in the experiment simulating drought stress, 17 and 18 were relatively weak inhibitors of ABA biosynthesis. As well, the aniline derivative 18 had a fairly pronounced (and undesirable) ABA-like effect on seed germination, with the thiophenyl analog 17 demonstrating a moderate effect.
[0066] Compounds with a tertiary alcohol at the junction of ring and side chain and either ketone or alcohol at C-4 were also envisioned to be possible inhibitors, as the general shape of the molecule and oxygen atom would be maintained. The keto allylic alcohol precursors 20, 21 and 22 were more conveniently prepared, affording both racemic and enantiomerically pure compounds. This was desirable as we had found earlier that the individual enantiomers 20 and 21 of the allylic alcohol 22 had different properties as competitive inhibitors of ABA perception. 34 The analog 20 competitively blocked ABA perception, while its enantiomer was a weak ABA agonist. On observing significant NCED inhibition with the racemic compound 13, comparable with that of ABM 9 and ABM-SG 10, we anticipated similar differences might be found in the present case, and the thioethyl derivatives of compounds 20 and 21 were synthesized and tested. Again, the stereochemistry of the analogs had an effect. Compound 12 inhibited the enzyme as strongly as the more xanthoxin-like compounds, while the other enantiomer 11 had reduced activity in the in vitro enzyme assay. Two diasteromeric hydroxy compounds 14 and 15 were synthesized to explore the effect of changing the oxidation level of the C-4 or position of the oxygen atom. In the in vitro enzyme assay, the hydroxyl compounds did not afford greater activity. Compound 16 was incorporated into the set of test molecules to determine if positioning the sulfur atom further from the cyclohexanone ring would have an effect on activity compared to that of 13.
Computational Analysis of SLCCD Inhibitor-Enzyme Complexes
[0067] In the ACO structure the binding pocket entrance is proposed to act as a bottleneck, arresting movement of 3-ON to the interior and positioning the C15-C15′ bond over the iron molecule in a trans conformation. 25 In contrast, AtNCED3 must accept substrate molecules with rings at both extremities, and thus it would be expected that the binding pocket entrance be sufficiently large to allow ring structures to enter the cavity. Therefore in contrast to ACO, AtNCED3 likely determines substrate positioning based on where the molecule interacts with the internal terminus of the binding pocket. Docking to the AtNCED3 model highlights that this is likely the case, as 3-ON was oriented with its C13-C14 bond over the iron, and the β-ionone ring pulled inside the tunnel entrance. Docking of 9-cis-neoxanthin 2 resulted in the epoxide ring being buried in the AtNCED3 catalytic pocket. This positioned the C11-C12 bond over the iron atom in a suitable position for catalytic cleavage at the expected location. These results emphasize the validity and potential utility of the AtNCED3 model.
[0068] The xanthoxin 4 molecule docked with its epoxide ring in the opposite orientation (similar to 3-ON) to that of the 9-cis-neoxanthin 2. While this likely does not represent its native orientation following cleavage of the 9-cis-neoxanthin 2 substrate, it emphasizes the accommodating size of the AtNCED3 entrance tunnel and that the preferred orientation of single ring containing molecules is with the ring pointing toward the entrance. Docking results for the SLCCD inhibitors seem to follow this preference with the hydroxylated rings preferentially pointing toward the entrance.
[0069] In the ACO crystal structure a coordinated water molecule occupies the fifth ligand position within the iron octahedral co-ordination structure. The water molecule, theorized to be an oxygen donor and required for catalytic activity, is located 3.2 Å from the C15 of the substrate and 2.07 Å from the non-heme iron atom. 25 Each of the three active SLCCD inhibitors docked with their heteroatoms (nitrogen or sulfur) within 2.7 Å of the iron atom such that they would be sufficient to occupy the coordinate space of the water molecule in the ACO structure and stop catalysis.
In Vivo Effects of SLCCD Inhibitors
[0070] The basic premise of this work lies in the design of inhibitors that bind to and inactivate the NCED enzyme responsible for the first committed step in ABA 1 biosynthesis. In a recent study on effects of drought stress on signaling and gene expression in Arabidopsis , it had been shown that the levels of ABA and its catabolites phaseic acid 6, dihydrophaseic acid 7 and ABA glucose ester 8 were all found to increase on imposition of the stress. 28 In the present study to compare the effects of potential inhibitors on ABA biosynthesis capacity, an osmotic stress treatment of Arabidopsis plants was substituted for the drought stress. ABA biosynthetic inhibitors were designed and tested and in the case of compound 13 were shown to significantly reduce the accumulation of ABA 1 and the catabolites 6, 7, and 8 in plants subjected to osmotic stress. While the rationale for inhibitor design was based on maintaining structural characteristics similar to the enzymes substrate and products to maximize specificity, this also meant that the inhibitors share structural characteristics with ABA 1 itself. Obviously an inhibitor of ABA 1 biosynthesis should not mediate ABA signaling.
[0071] Toward assessing the ABA-like character of the inhibitors their ability to mediate known ABA 1 effects at the levels of seed germination and gene regulation were determined. In general, the SLCCD inhibitors were found to be weaker germination inhibitors than (+)-ABA 1, with compound 13 having 60-70% less effect. Interestingly, low concentrations of compounds 13 and 17 had slight promotion effects on seed germination. As well, treatment of mannitol-stressed plants with compound 13 led to a reduction of transcript levels for three genes known to be (+)-ABA 1 inducible. 5,30 The reduction of transcription mediated by this inhibitor is in agreement with previous observations made for alternate inhibitors and likely results from the reduction of endogenous ABA 1 levels. 17 Overall, these results emphasize that SLCCD inhibitor 13 does not generally simulate ABA-inducible responses and thus does not maintain ABA-like characteristics.
[0072] Finally, these pilot in vivo studies demonstrate that mannitol stress leads to induction of AtNCED3 gene expression as reported previously. 7 While stress induced, it is not clear whether AtNCED3 is specifically ABA-inducible. But from the results reported here, it is clear that application of the SLCCD inhibitors significantly reduces AtNCED3 mRNA levels under stress conditions, which would further contribute to reducing ABA 1 biosynthesis in planta. While this characteristic was not specifically sought in designing the inhibitors, in terms of the overall objective of inhibiting ABA 1 biosynthesis, a reduction in the primary biosynthetic enzyme is a very useful side effect
[0073] The relatively lesser effects of inhibitors 17 and 18 in planta were surprising considering their effectiveness in vitro and docking results in silico. This lowering of efficacy in moderating ABA levels in vivo could be due to many factors, including stability of the different compounds in the plant and the presence of the hydrophobic aromatic rings in both 17 and 18 structures, possibly reducing their permeability through the roots and transport to the site of action. The discrepancy between in vitro and in vivo results is consistent also in the AtNCED3 expression profiling where 13 led to the highest reduction of stress-induced gene expression.
Synthesis of ABA Analogue Inhibitors
Example 1
(4S,5R)-(3′Z)-4-(5′-(Ethylthio)-3′-methylpent-3′-en-1′-ynyl)-4-hydroxy-3,3,5-trimethylcyclohexanone (11)
[0074] A solution of alcohol 20 20 (25 mg, 0.1 mmol), ethyl disulfide (25 μL, 0.2 mmol) and n-Bu 3 P (49 μL, 0.2 mmol) in CH 2 Cl 2 (1.5 mL) was stirred at room temperature for 4.5 h. Ethanol (1 mL) was added to the reaction and the resulting mixture was stirred for 20 min. Ethanol was removed by evaporation and CH 2 Cl 2 (15 mL) was added. The organic phase was washed with 0.5 N NaOH and brine successively, dried and concentrated to give a residue which was purified by FCC (ethyl acetate/hexane, 15:85 v/v) to provide 11 (19.2 mg, 62%) and recover 20 (4 mg, 19%).
[0075] [α] 25 D -16 (c 0.48, CHCl 3 ); IR (KBr): 3463, 2975, 2872, 1688 cm −1 ; 1 H NMR (CDCl 3 ) δ: 5.76 (1H, dt, 1.25, 7.75 Hz, ═CH), 3.31 (2H, d, 8.75 Hz, CH 2 S), 2.65 (1H, d, 14.25 Hz, H-2), 2.48 (2H, q, 7.5 Hz, SCH 2 CH 3 ), 2.29 (3H, m, H-5 & H-6), 2.08 (1H, d, 14.25 Hz, H-2), 1.89 (3H, s, CH 3 ), 1.22 (3H, t, 7.5 Hz, SCH 2 CH 3 ), 1.20 (3H, s, CH 3 ), 1.14 (3H, s, CH 3 ), 0.97 (3H, s, CH 3 ); 13 C NMR (CDCl 3 ) δ: 209.2, 134.2, 119.5, 92.6, 86.8, 77.4, 52.9, 47.0, 42.2, 37.4, 31.6, 25.9, 25.4, 23.2, 20.8, 16.6, 14.9; HRMS EI + m/z calc. for C 17 H 26 O 2 S: 294.1654. found: 294.1655.
Example 2
(4R,5S)-(3′Z)-4-(5′-(Ethylthio)-3′-methylpent-3′-en-1′-ynyl)-4-hydroxy-3,3,5-trimethylcyclohexanone (12)
[0076] A solution of alcohol 21 20 (28 mg, 0.11 mmol), diethyl sulfide (28 μL, 0.22 mmol) and n-Bu 3 P (55 μL, 0.22 mmol) in CH 2 Cl 2 (2 mL) was stirred at room temperature for 6 h. Work up as described above, followed by purification by FCC (ethyl acetate/hexane, 15:85 v/v) to afford 12 (22 mg, 63%).
[0077] [α] 25 D +15 (c 1.0, CHCl 3 ). The spectral characterization data was identical to enantiomer 11.
Example 3
(4S,5R/4R,5S)-(3′Z)-4-(5′-(Ethylthio)-3′-methylpent-3′-en-1′-ynyl)-4-hydroxy-3,3,5-trimethylcyclohexanone (13)
[0078] A solution of allylic alcohol 22, protected as the neopentylglycol ketal 20 , (34 mg, 0.1 mmol), ethyl disulfide (34 μL, 0.27 mmol) and n-Bu 3 P (62 μL, 0.25 mmol) in CH 2 Cl 2 was stirred at room temperature for 4.5 h. Work up as described above, followed by purification by FCC (ethyl acetate/hexane, 10:90 v/v) to afford the sulfide (22.1 mg, 58%).
[0079] 1 H NMR (CDCl 3 ) δ: 5.67 (1H, ddq, 1.5, 7.75, 7.75 Hz, ═CH), 3.54 (2H, d, 11.25 Hz, OCH 2 ), 3.36 (2H, ddd, 1.75, 11.25, 13.25 Hz, OCH 2 ), 3.31 (2H, dd, 0.75, 7.75 Hz, SCH 2 ), 2.48 (2H, q, 7.5 Hz, SCH 2 CH 3 ), 2.24 (1H, dd, 3.25, 14.25 Hz, H-2), 2.18 (1H, m, H-5), 1.96 (1H, dt, 3.25, 13.5, H-6), 1.87 (3H, d, 1.0 Hz, CH 3 ), 1.57 (1H, dd, 13.5, 13.5 Hz, H-6), 1.46 (1H, d, 14.25 Hz, H-2), 1.22 (3H, t, 7.5 Hz, CH 3 ), 1.12 (3H, s, CH 3 ), 1.09 (3H, s, CH 3 ), 1.04 (3H, d, 7.5 Hz, CH 3 ), 1.04 (3H, s, CH 3 ), 0.82 (3H, s, CH 3 ).
[0080] To a solution of the ketal protected sulfide (160 mg, 0.4 mmol) in acetone (5 mL) was added 2N HCl (8 drops). The mixture was stirred at room temperature for 40 min. After evaporation of acetone, ether was added and washed with sat. NaHCO 3 , dried and concentrated to give a residue which was purified by FCC (ethyl acetate/hexane 20:80 v/v) to provide 13 (100 mg, 80%). The spectral characterization data was identical to pure enantiomer 11.
Example 4
(1S,4R,6R)-(3′Z)-1-(5′-(Ethylthio)-3′-methylpent-3′-en-1′-ynyl)-2,2,6-trimethylcyclohexane-1,4-diol (14)
[0081] A solution of allylic alcohols 23 and 24 20 (200 mg, 0.55 mmol), (C 2 H 5 S) 2 (102 μL, 0.83 mmol) and n-Bu 3 P (203 μL, 0.83 mmol) in CH 2 Cl 2 (5 mL) was stirred at room temperature for 6 h. Work up as described above, followed by purification by FCC (ethyl acetate/hexane, 5:95 v/v) to provide 25 (41 mg, 17%), 26 (18.4 mg, 8%) and recovery of the unreacted starting material (70 mg, 35%).
[0082] For 25: 1 H NMR (CDCl 3 ) δ: 5.67 (1H, dt, 1.5, 7.75 Hz, ═CH), 3.92 (1H, m, H-4), 3.32 (2H, dd, 0.75, 7.75 Hz, CH 2 S), 2.49 (2H, q, 7.25 Hz, SCH 2 CH 3 ), 2.32 (1H, m, H-6), 1.87 (3H, d, 1.0 Hz, CH 3 ), 1.76 (1H, br s, OH), 1.62 (1H, dd, 3.5, 14.25 Hz, H-3), 1.57 (2H, m, H-5), 1.49 (1H, d, 14.25 Hz, H-3), 1.23 (3H, t, 7.25 Hz, SCH 2 CH 3 ), 1.20 (3H, s, CH 3 ), 1.06 (3H, s, CH 3 ), 1.04 (3H, d, 6.5 Hz, CH 3 ), 0.86 (9H, s, SiCMe 3 ), 0 (6H, s, SiMe 2 ).
[0083] To a solution of 25 (41 mg, 0.1 mmol) in THF (1.5 mL) was added TBAF (1 M solution in THF, 0.5 mL, 0.5 mmol). The reaction mixture was stirred at room temperature for 1 day and diluted with ether. The mixture was washed with water (10 mL×3), dried, concentrated and fractionated by FCC (10% ethyl acetate/hexane, 10:90 v/v increased to 35:65 v/v) to provide 14 (21.3 mg, 71%).
[0084] [α] 25 D −13 (c 0.94, CH 2 Cl 2 ); IR (KBr): 3332, 2976, 2879, 1450 cm −1 ; 1 H NMR (CDCl 3 ) δ: 5.67 (1H, dt, 1.5, 7.75 Hz, ═CH), 4.0 (1H, m, H-4), 3.30 (2H, dd, 1.0, 7.75 Hz, CH 2 S), 2.47 (2H, q, 7.5 Hz, SC 2 H 5 ), 2.32 (1H, m, H-6), 1.85 (3H, s, CH 3 ), 1.63 (4H, m, H-5 & H-3), 1.19 (3H, t, 7.5 Hz, SC 2 H 5 ), 1.19, (3H, s, CH 3 ), 1.08 (3H, s, CH 3 ), 1.03 (3H, d, 6.5 Hz, CH 3 ); 13 C NMR (CDCl 3 ) δ: 133.2, 120.0, 94.1, 85.7, 79.1, 66.8, 44.5, 40.1, 38.8, 31.9, 31.6, 27.5, 25.2, 23.3, 23.1, 16.1, 14.9; HRMS Cl + NH 3 m/z calc. for C 17 H 32 NO 2 S: 314.2154. found: 314.2162.
Example 5
(1R,4R,6R)-(3′Z)-1-(5′-(Ethylthio)-3′-methylpent-3′-en-1′-ynyl)-2,2,6-trimethylcyclohexane-1,4-diol (15)
[0085] To a solution of 26 20 (18.4 mg, 0.045 mmol) in THF (1.2 mL) was added TBAF (1.0 M solution in THF, 0.13 mL, 0.13 mmol). The reaction was stirred at room temperature for 1 day. Work up as for 14 to provide product 15 (8.5 mg, 64%) and recovered starting material (4.5 mg, 24%).
[0086] [α] 25 D +10 (c 0.25, CH 2 Cl 2 ); IR (KBr): 3388, 2968, 2922, 1458 cm −1 ; 1 H NMR (CDCl 3 ) δ: 5.71 (1H, dt, 1.5, 7.75 Hz, ═CH), 3.87 (1H, m, H-4), 3.33 (2H, dd, 1.0, 7.75 Hz, CH 2 S), 2.51 (2H, q, 7.7 Hz, SC 2 H 5 ), 2.00 (1H, m, H-6), 1.88 (3H, d, 1.5 Hz, CH 3 ), 1.67 (1H, ddd, 2.5, 4.5, 12.75 Hz, H-5), 1.57 (1H, dd, 11.5, 12.5 Hz, H-5), 1.35 (1H, dd, 12.5, 24.25 Hz, H-3), 1.23 (3H, t, 7.25 Hz, CH 3 ), 1.13 (3H, s, CH 3 ), 1.07 (3H, d, 6.5 Hz, CH 3 ), 1.02 (3H, s, CH 3 ); 13 C NMR (CDCl 3 ) δ: 133.4, 119.9, 93.9, 86.3, 78.3, 66.2, 46.8, 41.7, 39.9, 35.7, 31.6, 27.0, 25.3, 23.2, 20.8, 16.5, 14.9; HRMS EI + m/z calc. for C 17 H 25 O 2 S: 296.1810. found: 296.1822.
Example 6
(1R,3S,6R)-(3′Z)-6-(5′-Hydroxy-3′-methylpent-3′-en-1-ynyl)-1,5,5-trimethyl-7-oxa-bicyclo[4.1.0]heptan-3-ol (28)
[0087] A mixture of compound 27 20 (18 mg, 0.1 mmol), (Z)-3-iodobut-2-en-1-ol (30 mg, 0.15 mmol), CuI (15 mg, 0.08 mmol) and (Ph 3 P) 4 Pd (23 mg, 0.02 mmol) in (i-Pr) 2 NH (0.3 mL) was stirred at room temperature for 17 h. Saturated NH 4 Cl solution was added to quench the reaction. The mixture was extracted with ether, dried, concentrated and fractioned by FCC (ethyl acetate/hexane, 60:40 v/v) to provide compound 28 (18.1 mg, 72%).
[0088] [α] 25 D −8.0 (c 1.2, CHCl 3 ); IR (KBr): 3333, 2959, 2923 cm −1 ; 1 H NMR (CDCl 3 ) δ: 5.85 (1H, ddq, 1.0, 6.75, 6.75 Hz, ═CH), 4.26 (2H, d, 6.75 Hz, ═CHCH 2 ), 3.79 (1H, m, H-3), 2.32 (1H, ddd, 1.75, 5, 14.25 Hz, H-2), 1.84 (3H, d, 1 Hz, CH 3 ), 1.74 (1H, br s, OH), 1.61 (1H, dd, 8.75, 14.25 Hz, H-2), 1.57 (1H, m, H-4), 1.47 (3H, s, CH 3 ), 1.22 (3H, s, CH 3 ), 1.19 (1H, dd, 10.5, 13.0 Hz, H-2), 1.08 (3H, s, CH 3 ); 13 C NMR (C 6 D 6 ) δ: 137.8, 119.1, 92.4, 84.3, 66.6, 63.8, 63.6, 61.5, 45.7, 40.0, 34.4, 30.0, 26.2, 22.9, 22.0; HRMS Cl + m/z calc. for C 15 H 23 O 3 : 251.1647. found: 251.1646.
Example 7
(1R,3S,6R)-(3′Z)-1,5,5-Trimethyl-6-(3′-methyl-5′-(phenylthio)-pent-3′-en-1′-ynyl)-7-oxa-bicyclo[4.1.0]heptan-3-ol (17)
[0089] A solution of alcohol 28 (56.6 mg, 0.23 mmol), phenyl disulfide (98.9 mg, 0.45 mmol) and n-Bu 3 P (112 μL, 0.45 mmol) in dry CH 2 Cl 2 (3 mL) was stirred at room temperature for 3 h. Ethanol (1 mL) was added to the reaction and stirred for 30 min. Ethanol was evaporated off and more CH 2 Cl 2 added. The organic phase was washed with 0.5 N NaOH, followed by water and then dried, concentrated, and fractionated by FCC (ethyl acetate/hexane, 30:70 v/v) to give product 17 (42 mg, 54%).
[0090] [α] 25 D −16 (c 0.84, CHCl 3 ); IR (KBr): 3438, 2961, 2924, 1583 cm −1 ; 1 H NMR (CDCl 3 ) δ: 7.31 (2H, m, C 6 H 5 ), 7.23 (2H, m, C 6 H 5 ), 7.14 (1H, m, C 6 H 5 ), 5.73 (1H, ddq, 1.0, 7.5, 7.5
[0091] Hz, ═CH), 3.82 (1H, m, H-3), 3.71 (2H, dd, 0.75, 7.5 Hz, CH 2 S), 2.34 (1H, ddd, 1.75, 5.0, 14.5 Hz, H-2), 1.81 (3H, d, 1.0 Hz, CH 3 ), 1.63 (1H, dd, 8.5, 14.5 Hz, H-2), 1.58 (1H, m, H-4), 1.47 (3H, s, CH 3 ), 1.23 (3H, s, CH 3 ), 1.21 (1H, m, H-4), 1.10 (3H, s, CH 3 ); 13 C NMR (CDCl 3 ) δ: 135.9, 132.9, 129.3, 128.9, 126.0, 120.7, 91.7, 84.2, 67.1, 63.8, 63.7, 45.8, 39.8, 34.4, 33.9, 29.9, 25.7, 22.9, 21.7; HRMS EI + m/z calc. for C 21 H 26 O 2 S: 342.1654. found: 342.1659.
Example 8
(1′R,4S,6′R)-(2Z)-5-(4′-Hydroxy-2′,2′,6′-trimethyl-7-oxa-bicyclo[4.1.0]heptan-1′-yl)-3-methylpent-2-en-4-ynal (29)
[0092] A mixture of alcohol 28 (89 mg, 0.36 mmol) and MnO 2 (774 mg, 8.9 mmol) in petroleum ether (10 mL) and ethyl acetate (5 mL) was stirred at room temperature for 4 h. The reaction mixture was filtered through a pad of Celite 545™ and washed with ethyl acetate. The combined filtrates and washings were concentrated and purified by FCC (ethyl acetate/hexane, 30:70 v/v) to afford aldehyde 29 (73.3 mg, 83%).
[0093] [α] 25 D −11 (c 3.0, CHCl 3 ); IR (KBr): 3456, 2918, 1601, 1593 cm −1 ; 1 H NMR (C 6 D 6 ) δ: 10.27 (1H, d, 8.0 Hz, CHO), 5.88 1H, dd, 0.75, 8.0 Hz, ═CH), 3.55 (1H, m, H-4), 2.03 (1H, ddd, 1.0, 5.0, 15.5 Hz, H-5), 1.46 (3H, d, 0.75 Hz CH 3 ), 1.36 (2H, m, H-3 and H-5), 1.27 (3H, s, CH 3 ), 1.13 (3H, s, CH 3 ), 1.11 (3H, s, CH 3 ), 0.99 (1H, dd, 10.0, 13.0 Hz, H-3); 13 C NMR (C 6 D 6 ) δ: 190.8, 140.1, 136.3, 98.4, 82.5, 67.0, 63.4, 45.4, 39.8, 34.3, 29.6, 26.1, 24.1, 21.8; HRMS Cl + m/z calc. for C 15 H 21 O 3 : 249.1491. found: 249.1489. 5.1.9.
(1R,3S,6R)-(3′Z)-1,5,5-Trimethyl-6-(3′-methyl-5′-(phenylamino)-pent-3′-en-1-ynyl)-7-oxabicyclo[4.1.0]heptan-3-ol (18)
[0094] A solution of aldehyde 29 (16 mg, 0.065 mmol) and aniline (10 μL, 0.11 mmol) in ethanol (1.5 mL) was refluxed for 30 min. The reaction mixture was cooled to room temperature and then NaBH 4 (7.4 mg, 0.2 mmol) was added. The resulting mixture was stirred at room temperature for 15 min. and water (3 mL) with glacial acetic acid (1 drop) was added. The ethanol was evaporated off and water phase was extracted with ether, dried, concentrated and fractionated by FCC (ethyl acetate/hexane, 35:65 v/v) to provide product 18 (17 mg, 81%).
[0095] [α] 25 D −13 (c 1.4, CHCl 3 ); IR (KBr): 3410, 2960, 1602, 1504 cm −1 ; 1 H NMR (C 6 D 6 ) δ: 7.15 (2H, m, C 6 H 5 ), 6.73 (1H, dd, 7.25, 7.25 Hz, C 6 H 5 ), 6.52 (2H, dd, 1.0, 8.5 Hz, C 6 H 5 ), 5.47 (1H, ddq, 1.5, 6.5, 6.5 Hz, ═CH), 3.80 (2H, m, CH 2 NH), 3.62 (1H, m, H-3), 2.09 (1H, ddd, 1.5, 5.0, 14.5 Hz, H-2), 1.67 (3H, d, 1.25, CH 3 ), 1.44 (3H, s, CH 3 ), 1.40 (2H, m, H-2 & H-4), 1.31 (3H, s, CH 3 ), 1.23 (3H, s, CH 3 ), 1.05 (1H, dd, 9.75, 13.0 Hz, H-4); 13 C NMR (C 6 D 6 ) δ: 148.4, 136.5 129.5, 119.8, 117.7, 113.2, 92.9, 84.5, 66.6, 63.6, 45.7, 44.1, 40.0, 34.4, 30.1, 26.2, 22.9, 22.0; HRMS TOF + m/z calc. for C 21 H 28 NO 2 : 326.2114. found: 326.2123.
Example 9
(2Z,4E)-5-(1′-Hydroxy-2′,2′,6′-trimethyl-4′-oxocyclohexyl)-3-methylpenta-2,4-dienyl 2-(thiophen-2″-yl)acetate (16)
[0096] To a solution of the allylic alcohol, racemic 20 from reference 20 , (34 mg, 0.1 mmol), Et 3 N (42 μL, 0.3 mmol) in CH 2 Cl 2 (1.5 mL) was added 2-thiopheneacetyl chloride (18 μL, 0.15 mmol). The reaction mixture was stirred at room temperature for 4 h and diluted with CH 2 Cl 2 . The organic phase was washed with saturated NaHCO 3 , dried, concentrated and fractionated by PTLC (ethyl acetate/hexane, 20:80 v/v) to the ketal protected thiophene ester (13 mg, 28%).
[0097] 1 H NMR (CDCl 3 ): 7.19 (1H, d, 1.25 Hz, SCH), 6.93 (2H, m, thiophene CH═CH), 6.67 (1H, d, 15.5 Hz, CH═CH), 5.98 (1H, d, 15.5 Hz, CH═CH), 5.47 (1H, t, 7.0 Hz, ═CHCH 2 O), 4.80 (2H, d, 7.0 Hz, CH 2 O), 3.82 (2H, s, COCH 2 ), 3.58 (2H, dd, 5, 10.25 Hz, OCH 2 ), 3.41 (2H, dd, 5, 10.25 Hz, OCH 2 ), 2.30 (1H, dd, 2.75, 14.5 Hz, H-3), 2.17 (1H, m, H-6′), 1.98 (1H, dd, 3.25, 14.25 Hz, H-5′), 1.86 (3H, s, CH 3 ), 1.40 (1H, d, 14.0 Hz, H-3′), 1.35 (1H, d, 14.0 Hz, H-3′), 1.12 (3H, s, CH 3 ), 1.06 (3H, s, CH 3 ), 0.85 (3H, s, CH 3 ), 0.78 (3H, s, CH 3 ), 0.77 (3H, d, 8.0 Hz, CH 3 ).
[0098] To a solution of the ketal protected thiophene ester (13 mg, 0.028 mmol) in acetone (1.5 mL) was added 2N HCl (2 drops). The mixture was stirred at room temp. for 1 h. After removing acetone, ether was added and washed with saturated NaHCO 3 , dried and concentrated to give a residue which was purified by FCC (ethyl acetate/hexane, 20:80 v/v) to provide 16 (8 mg, 75%).
[0099] IR (KBr): 3517, 2959, 1714 cm −1 ; 1H NMR (CDCl 3 ) δ: 7.19 (1H, d, 1.5 Hz, SCH), 6.93 (2H, m, thiophene CH═CH), 6.80 (1H, d, 15.5 Hz, CH═CH), 6.12 (1H, d, 15.5 Hz, CH═CH), 5.54 (1H, t, 7.0 Hz, ═CHCH 2 O), 4.81 (2H, d, 7.0 Hz, CH 2 O), 3.82 (2H, s, COCH 2 ), 2.46 (1H, d, 15.0 Hz, H-3′), 2.30 (2H, m, H-5′ & H-6′) 2.13 (2H, m, H-5′ & H-3′), 1.90 (3H, s, CH 3 ), 1.02 (3H, s, CH 3 ), 0.90 (3H, s, CH 3 ), 0.85 (3H, d, 6.5 Hz, CH 3 ); 13 C NMR (C 6 D 6 ) δ: 209.3, 170.4, 136.7, 135.6, 135.0, 129.9, 128.2, 126.8, 125.1, 123.1, 78.1, 61.0, 52.9, 47.1, 41.6, 37.4, 35.4, 25.2, 22.8, 20.9, 15.9; HRMS EI + m/z calc. for C 21 H 28 O 4 S: 376.1708. found: 376.1720.
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[0142] Other advantages that are inherent to the structure are obvious to one skilled in the art. The embodiments are described herein illustratively and are not meant to limit the scope of the invention as claimed. Variations of the foregoing embodiments will be evident to a person of ordinary skill and are intended by the inventor to be encompassed by the following claims. | A compound of formula (I):
wherein:
R 1 is —SR 10 , —O—C(O)—R 11 , —NR 12 R 13 , where R 10 is a C 1-8 -alkyl group or a phenyl group unsubstituted or substituted by a C 1-4 -alkyl group, R 11 is a thiophenenyl, furanyl or pyrrolyl group, R 12 is H or a C 1-4 -alkyl group and R 13 is a C 1-8 -alkyl group or a phenyl group unsubstituted or substituted by a C 1-4 -alkyl group; R 2 is H or a C 1-4 -alkyl group; R 3 and R 4 are independently H or C 1-4 -alkyl groups; R 5 and R 6 are independently H, OH or OR 14 , or taken together are ═O, where R 14 is a protecting group; R 7 is H or a C 1-4 -alkyl group; and, R 8 is H, R 9 is OH and R 15 is H, or R 15 is H and R 8 and R 9 taken together are —O—, or R 9 is OH and R 8 and R 15 taken together form a bond; and, R 18 and R 19 are both H, or R 18 and R 19 taken together form a bond,
or a plant physiologically acceptable salt thereof is useful for inhibiting 9-cis-epoxycarotenoid dioxygenase (NCED) in a plant or seed and is therefore useful for regulating ABA biosynthesis in the plant or seed. | 2 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims priority to and benefit of Australian Provisional Patent Application No. 2011905023, filed Dec. 2, 2011, which is hereby incorporated by reference herein as if fully set forth in its entirety.
FIELD OF THE INVENTION
[0002] This invention relates to the taking of samples from blast-holes at a mine site and the processing of those samples. In particular this invention relates to mobile sampling and processing facilities that can be carried on a vehicle or towed to a blast-hole to commence operation.
BACKGROUND OF THE INVENTION
[0003] The efficient operation of an open cut mine is heavily dependent on the data collected from constant sampling to determine the concentration of ore in the sample. Traditionally where blast-holes are required as part of the mining process, sampling is done by taking multiple auger samples from each blast-hole cone, bagging them and tagging them with identification for subsequent analysis back at a lab. This data gives critical information regarding the yield and the distribution of ore so that appropriate processing of the ore can be determined. Many mines struggle to reach their full potential due in part to unreliable and inaccurate testing systems.
[0004] The current facilities consist of a centralised laboratory, sometimes servicing multiple mines. One of the critical issues concerning the laboratories inability to give reliable and accurate results relates to problems in collecting the samples from the blast-holes. Typically this is a manual operation involving a team of two workers. The team drives out to the particular area of the mine after the blast-hole drilling operation has completed, and then manually takes samples from the hole cone using a cumbersome and heavy hand held auger to perform the drilling operation in order to collect the sample. Multiple drillings of a blast-hole cone are required to improve accuracy, and the samples are collected in a bag and appropriately tagged with relevant location information.
[0005] There are a number or problems associated with this method of collecting samples:
1. Firstly, because it is a manual task, different teams can yield different results. One team may be diligent in acquiring samples from multiple locations on the blast-hole cone, while others may not. Manual operation restricts the sampling tool selection (due to ergonomic constraints) and can cause significant mixing as the tool penetrates a cone, thus causing the sample to be less representative. 2. Secondly, operation of the equipment is arduous and heavy back breaking work, also the samples collected are placed into a bag, and these typically weigh 10 to 12 kgs. As the team gets fatigued, the quality of their sampling may degrade and the quality of the sampling and the weight of the bag collected may also diminish. A smaller sample bag results in a less representative sample. 3. Thirdly, the time it takes to get a sample manually collected from the blast-hole cone, then subsequently processed and analysed at the lab is critical to maximizing the efficiency of the mine's operation. It is estimated that the time it takes to extract the relevant information from taking the sample to completing the analysis in the laboratory is from 10 to 30 hours. This time adversely affects production which in turn degrades the efficient operation of the mine. 4. Finally many mines operate in difficult and arduous regions of the Earth. Some mines operate in extreme heat and/or bitter cold. These environmental factors also may have a negative impact on the efficiency of the sample recovery teams working at the blast-hole.
[0010] Typically one team is expected to take samples from 65 to 75 blast-hole cones per shift and spend approximately 10 minutes at each hole and collect a 10 to 12 kg bag that is placed into a storage area on their vehicle for subsequent collection and delivery to the laboratory for further processing and analysis. Significant logistical effort is required in transporting the samples to the lab for analysis.
[0011] It is an object of the present invention to alleviate at least some of the problems aforementioned.
DISCLOSURE OF THE INVENTION
[0012] The present invention is a self-contained mobile sampling and processing facility for use at a mine having at least one blast-hole. The sampling and processing facility includes at least one primary robotic arm that carries at least one sampling tool. The primary robotic arm and sampling tool is controlled by robotic arm and sampling tool movement controller means. The primary robotic arm is capable of self-determining the direction, distance and shape of a nearby blast-hole cone, then subsequently positioning itself so that the sampling tool is able to engage with the blast-hole cone and retrieve a sample from it without significant mixing or stirring of the cone, or a localised region of the cone. The sample is then deposited into the processing facility.
[0013] The means that enable the primary robotic arm to self-locate the blast-hole include a camera, and a distance sensor.
[0014] Optionally the means that enable the primary robotic arm to self-locate the blast-hole may also include manual input by the operator.
[0015] One or more primary robotic arms may be carried on one or more secondary robotic arms that in combination gives extended reach and maneuverability. The robotic arms may be mounted in an inverted orientation to increase the reach and maneuverability.
[0016] The mobile sampling and processing facility is carried on a vehicle and/or towed on a trailer.
[0017] Either the primary robotic arm or the combination of primary and secondary robotic arms is capable of moving and operating on either side of the vehicle and/or towed trailer.
[0018] The processing facility includes a crusher into which the sample is deposited by the robotic arm.
[0019] The processing facility includes conveyancing means onto which the output from the crusher is fed subsequent to the crushing operation being completed.
[0020] The processing facility may include splitter means that receive the crushed sample from the conveyor means and split out a portion of the crushed sample.
[0021] The processing facility includes bagging means that receive the split out portion from the splitter means and collect it into a bag.
[0022] Preferably the bagging means is capable of receiving the sample directly from the robotic arm(s) without any preceding crushing, conveyance or splitting operations, if the operator deems that the sample is too wet for any or all of the preceding operations to be undertaken.
[0023] Preferably when the samples are wet, and the bagging means are receiving the sample directly from the robotic arm(s), the acceptable weight range of a filled sample bag is between 5 and 20 kilograms.
[0024] The robotic arm and sampling tool controller means will control at least one primary robotic arm and its associated sampling tool to continue to take samples from a variety of locations around the blast-hole cone, and continue to feed them into the processing facility until a predetermined number of samples have been taken from the blast-hole cone.
[0025] Preferably the robotic arm and sampling tool controller means includes both a manual and an automatic safety cut-out that only allows the robotic arm(s) and sampling tool(s) to be operated while the operator is within the safe confines of the vehicle cabin, and when appropriate sensor means, for example opening sensors fitted to the doors, or weight sensors in the seats, are triggered by a person alighting the vehicle during operation, or when the manual means are activated by an operator, the robotic arms and any ancillary exposed machinery is brought to a safe stop.
[0026] Preferably the facility includes proximity sensors around the vehicle that are capable of determining when a person, animal or object has moved within a safety exclusion zone around the facility during operation, thereby tripping proximity sensors which causes the robotic arm(s) and any other exposed machinery to be brought to a safe stop.
[0027] Preferably the proximity sensors include, but are not just limited to, all or a subset of video cameras, infra read detectors, RFID means, laser means, RADAR means and GPS means.
[0028] The processing facility includes weighing means that weigh the bag as it collects the split out portion.
[0029] The weighing means provide confirmation that the sample collected in the bag is within a predetermined acceptable weight range.
[0030] Alternatively the processing facility includes feedback means that are controlled by the weighing means. The feedback is sent to the robotic arm and sampling tool movement controller means so that the sampling tool will continue taking samples from the blast-hole cone in different locations relative to the blast-hole, and continue to feed them to the processing facility until the weight of the bag falls within a pre-determined acceptable weight range.
[0031] The pre-determined acceptable weight of the bag may be in the range of 1 to 5 kilograms, but more typically the acceptable weight range of the bag is between 1.8 and 1.9 kilograms.
[0032] Alternatively the sampling tool continues to take samples at different locations from the blast-hole cone and these are fed into the crusher means and the crusher means includes temporary storage means that receives the output from the crusher and holds it, thereby allowing the crushed output from multiple samples to be aggregated, before the aggregate is deposited onto the conveyance means.
[0033] Optionally the sampling tool may be an auger.
[0034] When the sampling tool is an auger, the robotic arm and sampling tool movement controller means co-ordinates the rotational speed and the rate of advancement of the auger so as to minimise any mixing of the cone, or a localised region of the cone, in order to maximise the quality of the sample taken.
[0035] The facility allows for quick interchange between sampling tools. Several tools are included in the facility for sampling different ore types. The range of tools includes but is not limited to the following augers:
a) A 100 mm nominal diameter auger with 20 mm sidewalls at a 66 mm nominal helix pitch. b) A 150 mm nominal diameter auger with 20 mm sidewalls at a 66 mm nominal helix pitch. c) A 150 mm nominal diameter auger with 20 mm sidewalls at a 101 mm nominal helix pitch. d) A 200 mm nominal diameter auger with 20 mm sidewalls at a 66 mm nominal helix pitch. e) A 200 mm nominal diameter auger with 20 mm sidewalls at a 136 mm nominal helix pitch.
[0041] Optionally any of the sampling tools have either reduced sidewalls or no sidewalls so that they are more suitable in facilitating the collection of wet samples.
[0042] Optionally, the facility includes an output storage buffer to allow the driver to remain in the vehicle for up to 1 hour before batch bagging and tagging between 10 and 20 samples.
[0043] Optionally the facility includes GPS means that enable the bag to be geotagged with relevant location data relevant to the particular blast-hole that the sample was retrieved from.
[0044] Optionally the facility includes Radio Frequency Identification (RFID) in the label that enables a particular bag to be easily identified.
[0045] The facility includes suitable batteries, and at least one DC to AC electrical inverter, and these supply all electrical power to the facility.
[0046] The batteries may be recharged by an alternator on the vehicle while the facility is in operation, and/or by including means that enable the batteries to be recharged by connection to a main power supply when the vehicle is parked at its depot.
[0047] So in accordance with the present invention a method of retrieving a sample from a blast-hole will now be described, including the steps of:
a. Driving a vehicle carrying the facility, and/or towing a trailer to the vicinity of at least one blast-hole to be sampled and parking it within the operational radius of the equipment, b. Engaging the facility so that the robotic arm and sampling tool commence to determine the distance, direction and shape of the relevant blast-hole cone and then automatically commence taking samples from the hole cone and feeding them into the processing facility, c. At the completion of the process, the robotic arm returns to its nominal rest state, d. The driver retrieves the sample bag from the bagging facility and seals and tags it with appropriate identification and places it into a storage area on the vehicle, e. The driver then places an empty bag into the bagging means, ready for the next operation on the next blast-hole.
[0053] Please note that the word arm where used throughout the specification should not be limited to just a single arm, but also should be construed to include at least a pair of robotic arms on the mobile sampling and processing facility.
BRIEF DESCRIPTION OF THE DRAWINGS
[0054] FIG. 1 shows an isometric view of a truck carrying the facility and a primary robotic arm mounted to a secondary robot arm (boom), and engaged with a nearby blast-hole.
[0055] FIG. 2 shows the sample taken by the auger from the blast-hole cone being deposited into the crusher.
[0056] FIG. 3 shows an isometric view of a truck carrying the self-contained facility with the robotic arm and auger in their nominal rest position.
[0057] FIG. 4 shows a schematic diagram of a preferred embodiment of the sample processing system and its feedback to the robotic arm and sampling tool controller.
[0058] FIG. 5 shows and alternative embodiment of the sample processing system utilising splitting means.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0059] The various elements identified by numerals in the drawings are listed in the following integer list.
[0060] Turning firstly to FIG. 1 , we see shown a mobile sampling and processing facility 1 carried on a flatbed truck 9 with the sampling and processing facility mounted. It should be noted that an alternative embodiment wherein the facility is towed on a trailer also falls within the scope of the present invention. The truck 9 is parked near a blast-hole cone 7 within the operational reach of the robotic arm 3 . The robotic arm 3 has self-aligned the sampling tool 5 so that the sampling tool can engage with the blast-hole cone 7 to extract a sample. This can all be initiated by the operator of the sampling and processing facility who is also the driver of the truck, while he remains seated in the vehicle. For comfort and protection from environmental hazards such as extreme hot or cold conditions, the driver is able to remain inside the air-conditioned vehicle during the majority of the operation. Upon initiation, the robotic arm 3 carrying the sampling tool 5 is able to acquire the target hole autonomously, then guide the sampling tool 5 to the vicinity of the hole 7 and determine the hole cone's size and shape. It is then able to control the position of the sampling tool relative to the hole so that the sampling tool 5 can commence retrieving samples from the blat-hole cone 7 . Multiple samples from the blast-hole cone are taken at a plurality of locations around the cone 7 to improve the reliability and accuracy of the sample taken.
[0061] In this example the sampling tool 5 is illustrated as an auger, however any suitable sampling tool could be used.
[0062] After each sample taken from the blast-hole cone 7 , it is then deposited in the processing facility via sampling chute 11 . The sample is directed by the sampling chute 11 into the crusher where the sample is crushed down to a uniform size. The sample is then passed onto a conveyor and moved to a bagging facility. This process is repeated as more and more samples are fed into the sampling chute 11 by the sampling tool 5 .
[0063] Once the predetermined number of samples has been taken from a variety of locations around the blast-hole cone 7 , the sampling process is complete, and the control means for the robotic arm and sampling tool ceases to perform sampling operations, and returns the robotic arms and sampling tool to their nominal rest position in which it is ready to be transported to the next blast-hole, or to return to the laboratory sample pickup location.
[0064] As best seen in FIG. 4 , the facility includes weighing means 19 that weigh the sample bag 17 to ensure the weight of the sample bag 17 is within the predetermined acceptable weight range. Once this is confirmed, the bag containing the sample is then closed and labeled with the appropriate dated label/tag relating to the location from where the sample was taken. This type of labeling and tagging may include geolocation data and may also include RFID capabilities to assist in identification and retrieval of the specific sample bag.
[0065] In an alternative embodiment, the contents of the bag are continuously weighed via the weighing means 19 during the operation of the sampling facility, and the facility continues to take and process samples until the weighing means determines that the weight of the sample bag 17 falls within a predetermined acceptable weight range. Then the weighing means instructs the control means for the robotic arm and sampling tool to cease taking samples, and returns the primary robotic arm and sampling tool to their nominal rest position in which it is ready to be transported to the next blast-hole, or to return to the laboratory sample pickup location. The bag containing the weighed sample is then closed and labeled and tagged with the appropriate date relating to the location from where the sample was taken. This type of tagging may include geolocation data and may also include RFID capabilities to assist in identification and retrieval of the specific sample bag.
[0066] FIG. 2 illustrates the sampling tool preparing to deposit a sample taken from the blast-hole cone into the sampling chute 11 .
[0067] FIG. 3 illustrates the robotic arm and sampling tool in their nominal rest position ready to be transported.
[0068] Turning now to FIGS. 4 and 5 , we can see the steps involved in processing the sample and having it bagged. The sample is first fed into a crusher 13 to ensure the sizes of the individual pieces of the sample are no greater than a set size. After the crushing stage, the sample is fed onto a conveyor means 14 and into a sample bag 17 . The bag is weighed by weighing means 19 which are capable of sending a feedback signal to the robotic arm and sampling tool control means 21 . When the bag reaches a set weight, the weighing means 19 instructs the robotic arm and sampling tool control means 21 to stop and move the robotic arm and sampling tool into their nominal rest position as shown in FIG. 3 . The bag 17 is then sealed and tagged by the operator with relevant geolocation data and RFID enabled label.
[0069] In an alternative embodiment, a sample splitter 23 , as shown in FIG. 5 , is placed in the operation so that only a portion of the sample collected is bagged, while the rest of the sample is discarded. In this embodiment, more samples are required to supply the bag with enough material to reach the set weight. The advantage of this is that the bag will contain more samples taken from more places around the blast-hole cone 5 , and therefore subsequent analysis of the sample included in the bag will more accurately represent the ore content at that particular blast-hole.
[0070] In another embodiment, that is more suitable when the blast-hole cone is wet, the facility may include alternative bagging means that receive the sample directly from the sampling tool without any preceding processing steps such as crushing, conveying or splitting. This mode of operation can be selected by the operator if he/she determines that the sample is too wet for crushing and/or splitting.
[0071] While the above description includes the preferred embodiments of the invention, it is to be understood that many variations, alterations, modifications and/or additions may be introduced into the constructions and arrangements of parts previously described without departing from the essential features or the spirit or ambit of the invention. It also falls within the scope of the present invention if there is an automatic sensing means, that is able to determine the moisture content of the sample, and automatically change the mode of operation for the facility when the moisture content of the sample reaches an acceptable limit. The acceptable weight range of the sample bag can also be modified inn this mode of operation so that is increased to allow for the weight of the moisture. In such cases the range may increase to between 5 and 20 kilograms.
[0072] A number of safety features can be included to protect the operator and other personnel in the area around the facility. The facility may include programmable safety controller means that help to ensure that the facility can only be operated when there is no humans, animals or other obstacles within a safety exclusion zone around the facility. Suitable sensor means, for example, cameras, infra-red sensors, RFID means, laser means and/or GPS means can send a feedback signal to the programmable safety controller, and if the sensor means detect an intrusion into the exclusion zone, it can facilitate an immediate shutdown of the facility, and cause the robotic arm to return to its nominal rest position, and all exposed machinery to cease operation. There can also be suitable sensor means within the cabin of the vehicle, such as door opening sensors of weight sensors in the seats that also shutdown the facility if it detects a person exiting the vehicle cabin during facility operation. Finally a section of strategically located manual shutdown switches can be placed on the facility and also inside the cabin to allow personnel to manually shutdown the facility if required.
[0073] It will be also understood that where the word “comprise”, and variations such as “comprises” and “comprising”, are used in this specification, unless the context requires otherwise such use is intended to imply the inclusion of a stated feature or features but is not to be taken as excluding the presence of other feature or features.
[0074] The reference to any prior art in this specification is not, and should not be taken as, an acknowledgment or any form of suggestion that such prior art forms part of the common general knowledge. | A self-contained mobile sampling and processing facility for use at a mine having at least one blast-hole that forms a blast-hole cone wherein the sampling and processing facility includes at least one primary robotic arm that carries at least one sampling tool, and the primary robotic arm and sampling tool is controlled by robotic arm and sampling tool movement controller means, and the primary robotic arm is capable of self-determining the direction, distance and shape of a nearby blast-hole cone, then subsequently positioning itself so that the sampling tool is able to engage with the blast-hole cone and retrieve a sample from it without significant mixing or stirring the cone, or a localised region of the cone, and then the sample is deposited into the processing facility. | 4 |
CROSS REFERENCE TO RELATED APPLICATIONS
The present application is a U.S. National Phase Application pursuant to 35 U.S.C. §371 of International Application No. PCT/EP2010/063514 filed Sep. 15, 2010, which claims priority to European Patent Application No. 09170689.5 filed on Sep. 18, 2009. The entire disclosure contents of these applications are herewith incorporated by reference into the present application.
FIELD OF INVENTION
The invention refers to an arrangement for determining a longitudinal position of a stopper for sealing a compartment of a medicament container.
BACKGROUND
Medicament containers such as syringes or ampoules usually comprise a hollow cylinder made of a pharmaceutical glass which is inert and chemically resistant against the drug stored inside, e.g. insulin. The container is sealed by a stopper or bung at one end of the cylinder which can be moved along the longitudinal axis of the cylinder in order to displace the drug and force it out of an outlet end which may be sealed by a piercable membrane. The stopper and the piercable membrane are conventionally made of an elastomere ensuring mechanical tightness under defined pressure conditions and long term germ impermeability. Other important parameters affecting the dimensioning and choice of materials of the stopper and the piercable membrane are the maximum force expected at the stopper and the number of allowable piercings of the piercable membrane.
Before filling in the drug and sealing the container, the quality of the inner surface of the cylinder is improved by siliconization, so static and dynamic frictions of the stopper are reduced. Furthermore siliconization improves the dosing accuracy and reduces the risk of glass particles being unhinged from the inner surface during long term storage.
DE 102 26 643 A1 discloses a stopper for an injection arrangement, the stopper comprising a stopper body, a stopper body support attached to a drive member of the injection arrangement and a sealing member for sealing a product container of the injection arrangement against the stopper body, wherein a membrane body is arranged in a cap-like manner at a proximal end of the stopper body wherein the sealing member is part of the membrane body. A sensor is provided for measuring a pressure exerted by the product on the proximal end of the membrane body. The sensor may be a pressure sensor.
US 2003/0125670 A1 discloses a medicament cartridge comprising a cylinder and a displaceable plunger. The cartridge is provided with an electrical element having specified electrical properties located on an external face of the plunger. The electrical element can take the form of a conductive disk or two conductive rings joined by a resistive pad. The device may be equipped with electrical contacts for contacting the electrical element.
WO 01/56635 discloses a container for a substance, which container comprises a coupling element for coupling the container with an administration unit for the substance, and a recognition element associated with the substance. The recognition element may be a bar code printed on a package, a chip card enclosed in the package or a magnetic card.
EP 1911479 A1 discloses a drug delivery device with magnetic connection between piston and piston rod. The device has a retaining volume for a product, and a piston movable in the retaining volume and/or relative to the retaining volume for discharging the product from the retaining volume. A piston rod is brought in effective connection with the piston. A coupling unit is provided in the piston for producing an electromagnetic or magnetic effect. The piston rod is provided with a permanent magnet, which produces an electromagnetic or magnetic effect. The piston and the piston rod are connected with each other by the coupling unit and the permanent magnet.
WO 9800187 A1 discloses a preparation delivery device comprising a) a container for the preparation having or being prepared for the arrangement of an opening, b) a mechanism operable to deliver at least part of the preparation in the container through the opening, c) attachment means for connection of the container to the mechanism and d) a sensor system arranged to detect at least one predetermined property of the container or its content. The device comprises a radiation transmitter arranged to irradiate the container position or a part thereof, a radiation receiver arranged to receive at least an area part of the radiation from the transmitter after the radiation has been affected by the container position and the receiver being designed to give an output response representative for the total radiation received from said area part. A method for operating the device comprises the step of transmitting radiation towards the container position or a part thereof to allow the radiation to be affected by the container position, receiving at least a part of the affected radiation from at least an area part of the container position in a non-imaging way and comparing the characteristics of the received radiation with a predetermined characteristic representative for the predetermined property to establish whether or not the predetermined property of the container is present.
US 2009137949 A1 discloses a nozzle assembly for a needle-free injection device. The nozzle assembly includes a nozzle body including an injectate chamber and one or more outlet orifices and a plunger configured to move through the injectate chamber toward the one or more outlet orifices. In some embodiments, the plunger includes a first portion and a second portion removably joined by a frangible region. In some embodiments, the plunger includes extensions configured to couple the plunger to a drive assembly of a needle-free injection device.
WO 02083209 A1 discloses a pump system for an infusion system includes a linear drive which minimizes the space occupied by the pump system in a portable housing. A motor and a motor drive shaft are arranged in parallel with, and adjacent to a syringe and lead screw. A gear box connects the drive shaft and lead screw to transfer rotational movements between them. A piston driving member, such as a cone or drive nut converts the rotational movement of the lead screw into linear motion of a syringe piston. Sensors detect when the piston or cone is in a “home” position and in an “end” position, respectively. A clamping member selectively clamps the lead screw against linear motion in at least a dispensing direction. Optionally, a proximity sensor is used to ensure that the cone and the piston are abutting during dispensing.
WO 9803215 A1 discloses means for optical dose measurements in syringes. Measurements of insulin quantities in a syringe are performed optically in an integrated insulin dose recorder/blood glucose meter. The syringe is placed in a holder before and after the administration of the dose. Liquid quantities in the syringe are determined by comparing optical response patterns of the syringe with calibration data stored in the device. Dose histories are downloaded to a patient computer for transfer to a clinician's computer. Standard or customized syringes (e.g., with marked plungers) may be used. Other wave energy carriers such as sound waves may also be used.
EP 1260244 A2 discloses a method of monitoring performance of an osmotic drug delivery system comprises implanting an osmotic drug delivery device having a movable piston in an animal, and determining a position of the implanted movable piston within the osmotic drug delivery device from an exterior of the animal. The position of the movable piston may be determined either by fluoroscopy, by X-ray, or by a magnetic gauge. The osmotic delivery device preferably comprises an implantable reservoir having at least one opening for delivering a beneficial agent contained within an interior of the reservoir to an organ of the animal, and an osmotic engine causing the release of the beneficial agent contained within the reservoir to the animal.
U.S. Pat. No. 6,068,615 discloses arrangements for inductance-based dose measurement in syringes. Measurements of insulin quantities in a syringe are performed inductively in an integrated insulin dose recorder/blood glucose meter. The syringe is placed in a holder before the administration of the dose, and the liquid quantity in the syringe is recorded. Inductors may be situated within the syringe and/or outside the syringe in various geometries. Standard or customized syringes may be used. Liquid quantities in the syringe are determined by comparing inductive response patterns of the syringe with calibration data stored in the device. Insulin dose and blood glucose histories are downloaded to a patient computer for transfer to a clinician's computer.
SUMMARY
It is an object of the invention to provide an improved arrangement for determining a longitudinal position of a stopper for sealing a compartment of a medicament container.
The object is achieved by an arrangement with the features of the independent claim 1 .
Advantageous embodiments are given in the dependent claims.
In the following the term proximal refers to a direction on a medicament container intended for attaching an outlet or an injection needle whereas the term distal refers to the opposite direction where a cylinder of the medicament container is open but sealed by a stopper.
According to the invention an arrangement for determining a longitudinal position of a stopper for sealing a compartment of a translucent medicament container for a liquid medicament comprises at least one light source and at least one photo sensitive sensor.
In the context of this specification the term translucent refers to a property of a material allowing at least partial transmission of light regardless of whether or not the light is scattered by the material or not. The term transparent by contrast refers to a condition where the light emitted from a light source on one side of the material is transmitted in a manner to create an image of the light source on the other side of the material, in other words to see through the material. In this sense, a transparent material is translucent, whereas a translucent material does not have to be necessarily transparent.
Either the at least one light source or the at least one sensor is laterally arrangeable next to the medicament container and extending over at least part of the length of the medicament container, preferably over at least almost the entire length. The respective other of the at least one light source and the at least one sensor sensor is arrangeable in a circular manner around a head of the medicament container, i.e. near a proximal end. The light source is arranged to emit light into the medicament container. The medicament container and/or the medicament is arranged to scatter the light so as to allow the sensor to detect it. The at least one sensor is connectable to a processor unit for processing sensor data.
In one embodiment the light source may be a circular light source arrangeable around the head of the medicament container, wherein an array of photo sensitive sensors is laterally arrangeable next to the medicament container. The processor unit is arranged to determine the stopper position by detecting a light/dark boundary caused by the laterally scattered light and the opaque stopper.
In an alternative embodiment an array of light sources is laterally arrangeable next to the medicament container. Each light source emits light with a characteristic distinct from the characteristics of the other light sources. The at least one sensor is arrangeable around the head of the medicament container and able to detect the light of each light source. The processor unit has information on the allocation of each light source and its characteristic and its position in the array. The processor unit is arranged to:
detect the characteristics of the light sources, determine which light source is currently emitting light into the medicament container, conclude, that the light sources whose characteristics are absent in the sensor data are currently obscured by the stopper, determine the stopper position by comparing these conclusions to the information on the allocation of the light sources, their characteristic and their position in the array.
The sensor may be arranged as a ring of sensors around the head of the medicament container.
The characteristic of each light source may be at least one wavelength or a range of wavelengths of the light. The characteristic of each light source may also be an individual a modulation of the light, such as a frequency or pattern of pulsed light, in order to make the light sources distinguishable.
In order to scatter the light from the at least one light source so as to allow the at least one sensor to detect the light, the medicament may be a cloudy liquid. Another approach for scattering the light could be a non-transparent medicament container, i.e. a medicament container, which is translucent but not transparent in order to scatter the light on its outer surface.
The processor unit may be arranged to determine a remaining quantity of the medicament in the medicament container from the longitudinal position of the stopper.
The arrangement may be part of an injection device.
In an example embodiment a stopper for sealing a compartment of a medicament container has at least one marker detectable through a lateral area of the medicament container. The stopper may be arranged in the medicament container moveably in a longitudinal direction. By detecting a longitudinal position of the marker a longitudinal position of the stopper can be determined with high accuracy provided the location of the marker with respect to the stopper dimensions is defined. Hence a remaining quantity of the medicament in the medicament container can be calculated for a given geometry of the medicament container and a given longitudinal position of the marker. This allows for an automatic dosing of the medicament, e.g. in an electromechanical insulin pen.
The marker may be a visual marker arranged in and/or on a lateral area of the stopper, the marker being distinguishable from the stopper material by its colour, e.g. by means of an optical sensor arranged outside the medicament container.
The visual marker may have the shape of a line or stripe or pattern. There may be more than one line or stripe arranged on the stopper, preferably in a circumferential direction of the stopper's lateral area. Thus the stopper may be rotated with respect to the sensor without affecting the accuracy of the determination of the longitudinal position.
The visual marker may be applied, e.g. printed onto or embedded into the lateral area of the stopper.
In another example embodiment the marker is a permanent magnet embedded in the stopper. A magnetic marker may be detected by a magnetic sensor, such as a Hall sensor. As opposed to the visual marker a magnetic marker does not require illumination in order to be detectable. Thus the longitudinal position may also be determined in poor lighting conditions or with medicaments which must not be exposed to light.
In yet another example embodiment the marker may be an electrically conductible marker embedded in the stopper, e.g. an iron core. Such a marker may be detected by inducing an electrical current and measuring the consequently altered magnetic field. This embodiment may also be used without illumination.
The stopper may be applied in an insulin pen injector, both for faster or slower reacting drugs. In this case the medicament container with the stopper is arranged inside the insulin pen. The sensor is arranged outside the medicament container but inside the insulin pen and connected to a processing unit for calculating the remaining quantity which can be displayed by an adequate means, e.g. an LED or LC display. The stopper may as well be applied in other injection devices and for different medicaments, e.g. anticoagulants.
The stopper according to either embodiment can comprise the same materials as conventional stoppers, such as elastomeres. The primary packaging, i.e. the glass cylinder of the medicament container may remain unchanged. Design modifications of the ampoule or the injection device are not required.
The medicament container may be a disposable device or a reusable device.
Further scope of applicability of the present invention will become apparent from the detailed description given hereinafter. However, it should be understood that the detailed description and specific examples, while indicating preferred embodiments of the invention, are given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 is a conventional art medicament container with a glass cylinder sealed by a piercable membrane and a stopper,
FIG. 2 is a stopper with a visual marker applied on a lateral area,
FIG. 3 is a stopper with an embedded magnetic marker,
FIG. 4 is a stopper with an embedded electrically conductible marker,
FIG. 5 is a medicament container with a laser triangulation sensor arranged behind the stopper,
FIG. 6 is a medicament container with a mirror arranged behind the stopper for deflecting the optical path of the laser triangulation sensor,
FIG. 7 is a medicament container with a chromatic confocal gauge,
FIG. 8 is a medicament container with a laterally arranged light source and a laterally arranged sensor,
FIG. 9 is a medicament container and a stopper with an integrated light source,
FIG. 10 is a medicament container with a laterally arranged light source and a sensor laterally arranged opposite the light source,
FIG. 11 is a medicament container with a mirror arranged behind the stopper for deflecting the light of a light source from behind the stopper to a laterally arranged sensor,
FIG. 12 is a medicament container with a mirror arranged behind the stopper for deflecting the light of a laterally arranged light source to a sensor arranged behind the stopper,
FIG. 13 is a medicament container with a circular light source arranged around a head of the medicament container and a laterally arranged sensor, and
FIG. 14 is a medicament container with a laterally arranged light source and a circular sensor arranged around a head of the medicament container.
DETAILED DESCRIPTION
FIG. 1 is a conventional art medicament container 1 with a hollow cylinder 2 sealed by a piercable membrane 3 and a stopper 4 . The piercable membrane 3 and the stopper 4 define a compartment 5 between for holding a substance, e.g. a medicament M. FIG. 11 shows the location of medicament M that is present in each of the cylinders illustrated in FIGS. 1 and 5 - 14 having a longitudinal axis L, even though not schematically shown in FIGS. 1 , 5 - 10 and 12 - 14 . The cylinder 2 may consist of glass. The stopper 4 can be moved along the longitudinal axis L of the cylinder 2 in order to displace the medicament and force it out of an outlet positioned at head 50 provided the piercable membrane 3 is pierced. The stopper 4 and the piercable membrane 3 may be made of an elastomere. The medicament container may have a label indicating its content, e.g. insulin.
FIG. 2 is a stopper 4 with a number of visual markers 6 . 1 applied on a lateral area of the stopper 4 . The visual marker 6 . 1 is detectable through a lateral area of the medicament container 1 which has to be transparent or translucent for this purpose. By detecting a longitudinal position of the visual marker 6 . 1 a longitudinal position of the stopper 4 can be determined with high accuracy provided the location of the visual marker 6 . 1 with respect to the stopper 4 dimensions is defined. Hence a remaining quantity of the medicament in the medicament container 1 can be calculated for a given geometry of the medicament container 1 and a given longitudinal position of the visual marker 6 . 1 .
The marker 6 . 1 may be distinguishable from the stopper 4 material by its colour, e.g. by means of an optical sensor (not shown) arranged outside the medicament container 1 .
The visual marker 6 . 1 may have the shape of a line or stripe as shown in FIG. 1 or the shape of another pattern. There may be only one or any other number of visual markers 6 . 1 . The lines or stripes are preferably arranged in a circumferential direction of the stopper's lateral area.
The visual marker 6 . 1 may be applied, e.g. printed onto or embedded into the lateral area of the stopper 4 .
FIG. 3 shows another embodiment of a stopper 4 with an embedded magnetic marker 6 . 2 , e.g. a permanent magnet. The magnetic marker 6 . 2 may be detected by a magnetic sensor (not shown), such as a Hall sensor. By detecting a longitudinal position of the magnetic marker 6 . 2 a longitudinal position of the stopper 4 can be determined with high accuracy provided the location of the magnetic marker 6 . 2 with respect to the stopper 4 dimensions is defined. Hence a remaining quantity of the medicament in the medicament container 1 can be calculated for a given geometry of the medicament container 1 and a given longitudinal position of the magnetic marker 6 . 2 .
There may be only one or any other number of magnetic markers 6 . 2 .
FIG. 4 shows yet another embodiment of a stopper with an embedded electrically conductible marker 6 . 3 , e.g. an iron core serving as a marker. Such a marker 6 . 3 may be detected by inducing an electrical current and measuring the consequently altered magnetic field. By detecting a longitudinal position of the marker 6 . 3 a longitudinal position of the stopper 4 can be determined with high accuracy provided the location of the marker 6 . 3 with respect to the stopper 4 dimensions is defined. Hence a remaining quantity of the medicament in the medicament container 1 can be calculated for a given geometry of the medicament container 1 and a given longitudinal position of the marker 6 . 3 .
There may be only one or any other number of electrically conductible elements 6 . 3 .
The stopper 4 may be applied in an insulin pen injector. The stopper may as well be applied in other injection devices and for different medicaments, e.g. one of an analgetic, an anticoagulant, an insulin derivate, heparin, Lovenox, a vaccine, a growth hormone, a peptide hormone, a proteine and complex carbohydrates.
There may be more than one compartment 5 and more than one stopper 4 in a medicament container 1 , e.g. in an injector where two or more substances have to be stored separately but mixed prior to use.
The features of the embodiments of FIGS. 2 and 3 may be combined with each other, i.e. the stopper 4 may comprise both the microchip 6 and the sensitive coating.
FIG. 5 shows a medicament container 1 with a laser triangulation sensor 9 arranged distally from the stopper 4 . The laser triangulation sensor 9 illuminates the distal or back side of the stopper 4 with a laser beam thereby creating a light spot. This light spot is detected by the laser triangulation sensor 9 and the distance between the laser triangulation sensor 9 and the stopper 4 is calculated by triangulation. The laser triangulation sensor 9 is linearly arranged behind the stopper 4 .
FIG. 6 is a variant of the embodiment of FIG. 5 . The laser beam from the laser triangulation sensor 9 to the stopper 4 and back is deflected by a mirror 10 arranged distally from the cylinder 2 . The laser triangulation sensor 9 is arranged laterally. This embodiment allows for reducing the overall length of the arrangement.
FIG. 7 is a medicament container 1 with a chromatic confocal gauge 11 arranged distally from the stopper 4 for determining the distance between the chromatic confocal gauge 11 and the stopper 4 . The distance is determined by emission of white light and measuring the dispersion of the light reflected by the stopper 4 .
FIG. 8 a is a lateral view of another embodiment of a medicament container 1 . FIG. 8 b is the related cross section through the stopper 4 . A light sensitive sensor array 7 is arranged laterally from the cylinder 2 and parallely aligned. The sensor array 7 extends over almost the entire length of the cylinder 2 . A light source 8 is arranged laterally from the cylinder 2 but angularly offset from the sensor array 7 in a manner to illuminate the cylinder 2 . Two reflective visual markers 6 . 1 are circumferentially arranged on the stopper 4 for reflecting the light from the light source 8 to the sensor array 7 . The intensity distribution of the light detected on the sensor array 7 indicates the stopper position. The number of visual markers 6 . 1 can be different from two. The light source 8 is preferably a surface emitting light source 8 extending over at least part of the length of the cylinder 2 .
FIG. 9 a is a lateral view of another embodiment of a medicament container 1 . FIG. 9 b is the related cross section through the stopper 4 . A light sensitive sensor array 7 is arranged laterally from the cylinder 2 and parallely aligned. The sensor array 7 extends over almost the entire length of the cylinder 2 . Two light sources 8 are arranged in the stopper 4 in a manner to illuminate the sensor array 7 . The intensity distribution of the light detected on the sensor array 7 indicates the stopper position. The number of light sources 8 in the stopper 4 can be different from two.
FIG. 10 a is an isometric view of another embodiment of a medicament container 1 . FIG. 10 b is a related cross section through the cylinder 2 distally from the stopper 4 . FIG. 10 c is a related cross section through the cylinder 2 proximally from the stopper 4 . A surface emitting light source 8 is arranged laterally from the cylinder 2 extending almost over the entire length of the cylinder 2 in a manner to shine into and through the cylinder 2 . Opposite the light source 8 a light sensitive sensor array 7 is arranged for detecting the light from the light source 8 transmitted through the cylinder 2 . The light is refracted in the cylinder 2 , wherein the refraction index in the compartment 5 filled with the liquid medicament proximally from the stopper 4 is higher than the refractive index of the air filled part of the cylinder 2 distally from the stopper 4 . Hence, the intensity of light detected by the sensor array 7 proximally from the stopper 4 is higher than distally from the stopper 4 thus allowing determining the longitudinal stopper position.
FIG. 11 is yet another embodiment of a medicament container 1 with a mirror 10 attached distally on the stopper 4 for deflecting the light of a light source 8 arranged distally to a laterally arranged sensor array 7 . The resulting light spot on the sensor array 7 indicates the longitudinal position of the stopper 4 .
FIG. 12 is a medicament container 1 with a mirror 10 attached distally on the stopper 4 for deflecting the light of a laterally arranged array 12 of light sources 8 to a light sensitive sensor 7 arranged distally. The array 12 of light sources 8 extends over almost the entire length of the cylinder 2 and comprises a number of independent light sources 8 , each of them arranged to be controlled independently and having a characteristic distinct from any other light source 8 in the array 12 . The characteristic may be at least one wavelength of the light or a range of wavelengths. It may likewise be a modulation of the light such as a pulse frequency. Depending on the longitudinal stopper position the sensor 7 receives the light of one light source 8 or a small number of individual light sources 8 . Due to the individual characteristic of the light of each light source 8 the longitudinal position of the stopper 4 can be determined.
FIG. 13 is another embodiment of a medicament container 1 with a circular light source 8 arranged around a head of the medicament container 1 near the proximal end. The light source 8 emits light into the cylinder 2 and illuminates the medicament in the compartment 5 from the proximal end. A light sensitive sensor array 7 is arranged laterally from the cylinder 2 and parallely aligned. The sensor array 7 extends over almost the entire length of the cylinder 2 . The cylinder 2 and/or the medicament is arranged to scatter the light so as to create a light/dark boundary on the sensor array 7 caused by the laterally scattered light and the opaque stopper 4 . The light may be scattered by the medicament being a cloudy liquid such as cloudy insulin. The light may also be scattered by a non-transparent cylinder 2 , i.e. a cylinder 2 which is translucent but not transparent.
The position of the light/dark boundary on the sensor array 7 represents the stopper position. The circular light source 8 may be an array 12 of light sources 8 .
FIG. 14 is yet another embodiment of a medicament container 1 with a laterally arranged array 12 of light sources 8 . The array 12 of light sources 8 extends over almost the entire length of the cylinder 2 and comprises a number of independent light sources 8 , each of them arranged to be controlled independently and having a characteristic distinct from any other light source 8 in the array 12 . The characteristic may be at least one wavelength of the light or a range of wavelengths. It may likewise be a modulation of the light such as a pulse frequency. A circular sensor 7 or array of sensors 7 is arranged around the head of the cylinder 2 .
Depending on the longitudinal stopper position the compartment 5 and the medicament in the compartment 5 is illuminated by all or a fraction of the light sources 8 . The cylinder 2 and/or the medicament is arranged to scatter the light so as to allow the sensor 7 or sensor array 7 to detect it. The light may be scattered by the medicament being a cloudy liquid such as cloudy insulin. The light may also be scattered by a non-transparent cylinder 2 , i.e. a cylinder 2 which is translucent but not transparent.
The sensor 7 or array of sensors 7 receives the light of at least one light source 8 or fraction of individual light sources 8 . A processor unit (not illustrated) connected to the sensor 7 or sensor array 7 has information on the allocation of each light source 8 and its characteristic and its position in the array 12 . The processor unit is arranged to detect the characteristics of the light sources 8 , determine which light source 8 is currently emitting light into the medicament container 1 , conclude, that the light sources 8 whose characteristics are absent in the sensor data are currently obscured by the stopper 4 , and determine the stopper position by comparing these conclusions to the information.
The longitudinal position of the stopper 4 in the medicament container 1 can be calculated from the determined distance between the stopper 4 and the respective sensor or gauge and a known relative position of the sensor/gauge and the medicament container 1 . | The invention refers to an arrangement and a method for determining a longitudinal position of a stopper for sealing a compartment of a translucent medicament container for a liquid medicament (M). The arrangement comprises a circular light source and a photo sensitive sensor, wherein either the light source or the sensor is laterally arrangeable next to the medicament container extending over at least part of the length of the medicament container, and wherein the respective other of the light source and the sensor is arrangeable in a circular manner around a head of the medicament container. The light source is arranged to emit light into the medicament container. The light is scattered by the medicament or medicament container and detected by the sensor. The sensor is connected to a processor unit for detecting the position of the stopper). | 0 |
This application is a continuation of U.S. patent application Ser. No. 10/801,410, filed Mar. 16, 2004, now U.S. Pat. No. 7,118,624, which is a continuation-in-part and claims priority from U.S. patent application Ser. No. 10/062,119, filed Jan. 31, 2002, now U.S. Pat. No. 6,706,108, which in turn claims priority from and the benefit of U.S. patent application Ser. No. 60/299,225, filed Jun. 19, 2001. The '410 application, from which this application is a continuation thereof, also claims priority from and is a continuation-in-part of U.S. application Ser. No. 10/736,337, filed Dec. 15, 2003, now abandoned, which application in turn claims priority from U.S. application Ser. No. 60/433,425, filed Dec. 13, 2002.
FIELD OF THE INVENTION
Applicant's invention relates to a method for making road base using primarily waste material from oil and gas waste solids and non-hazardous industrial waste or natural occurring porous or semi-porous material to create a asphalt stabilized road base that is environmentally safe and meets industry standards for quality materials. More particularly, it relates to combining, in a cold batch mixing process, treated oil and gas waste material with aggregate to provide the major components for the roadbed base material.
BACKGROUND OF THE INVENTION
Because of their importance in all aspects of both business and private life, the construction of roads has historically been of prime importance to a society. That importance remains today. However, it has also become more apparent in recent years that most resources are not infinite but rather, are depletable. Additionally, disposing of waste materials is becoming harder and harder due both to space limitations and liability resulting from waste materials entering the environment.
Thus, there is a need for developing methods to recycle waste products into new, usable products. If the components of roadbeds can be obtained from the waste products of other products and processes, then both waste product production is decreased and new product consumption is decreased. Further, it is advantageous to recycle waste products due to the economic advantage of using recycling materials and thus compounding return on the original costs of the products.
SUMMARY OF THE INVENTION
The primary focus of the invention is the treatment of oil and gas waste for use with other materials to make a suitable road base material. Treatment of oil and gas waste is done to remove at least a portion of a liquid component, typically primarily oil and water to yield a treated oil and gas waste portion which is then combined with an aggregate and a binder and stabilizer to produce a suitable road base material. The treatment of the oil and gas waste, while yielding a liquid portion may also yield other recyclable or useable products such as clean mud. Clean mud is a product often desired by oil and gas well drillers. Thus, it is the desired result of the present invention of using oil and gas waste material treated such that it is converted into a material that is useable and, excepting perhaps “waste water” which may be reinjected, yields environmentally friendly, economically valuable components.
Turning to the separation of the liquid component from the oil and gas waste material it is anticipated by the present invention that there are a number of methods of liquid portion removal. One such method is a novel means of stacking of oil and gas waste, to yield gravity induced separation of some of the liquid portion from the solid portion. Another method is mechanical separation, such as by a centrifuge. A third method is mixing with a dry material, such, for example, as soil, overburden, or caliche limestone.
The present invention provides a novel method to produce road base material using waste products from one or both of two industries: oil and gas well drilling and from construction and/or demolition and manufacturing projects. The present invention also provides for a novel road base composition. The oilfield waste is typically comprised of hazardous and/or non-hazardous oilfield solid or liquid waste such as water based drilling fluid, drill cuttings, and waste material from produced water collecting pits, produced formation sand, oil based drilling mud and associated drill cuttings, soil impacted by crude oil, dehydrated drilling mud, waste oil, spill sites and other like waste materials tank bottoms, pipeline sediment and spillsite waste. Oilfield waste may include waste or recycled motor oil, petroleum based hazardous or non-hazardous materials, such oilfield waste materials are collectively referred to as “oil and gas waste material.” They typically have a solid component and a liquid component, the liquid component including quantities of oil and water. The solid components may be, in part, particulate.
An aggregate component of the road based material may include a non-hazardous industrial waste as defined in more detail below or any natural occurring stone aggregate such as limestone, rip rap, caliche, sand, overburden, or any other naturally occurring porous material. There may or may not be preparation of the aggregate material prior to combining with the treated oil and gas material to form the primary component of the road based material of Applicant's present invention.
The construction and/or demolition or manufacturing waste component of the aggregate material is typically comprised of non-hazardous industrial waste such as waste concrete, waste cement, waste brick material, gravel, sand, and other like materials obtained as waste from industrial construction, demolition sites, and/or manufacturing sites. Such materials are collectively referred to as “non-hazardous industrial waste.”
One application of the method of the present invention provides for recycling the oil and gas waste material and the non-hazardous industrial waste to combine to produce road base. Another application of the present invention provides for recycling the oil and gas waste material and an aggregate including limestone, rip rap, caliche, or any naturally occurring porous or semi-porous material to combine to produce road base. Hydration and mixing of the treated oil and gas waste material and aggregate along with a binder such as cement, fly ash, lime, kiln dust or the like, will achieve an irreversible pozzolanic chemical reaction necessary for a road base. An asphalt emulsifier may be included in the binder to manufacture asphalt stabilized road base. The ingredients are typically mixed in a cold batch process.
Solid waste from the oil and gas waste material typically contains naturally occurring aluminas and silicas found in soils and clays. The added pozzolan will typically contain either silica or calcium ions necessary to create calcium-silica-hydrates and calcium-aluminatehydrates. A pozzolan is defined as a finally divided siliceous or aluminous material which, in the presence of water and calcium hydroxide will form a cemented product. The cemented products are calcium-silicate-hydrates and calcium-aluminate-hydrates. These are essentially the same hydrates that form during the hydration of Portland Cement. Clay is a pozzolan as it is a source of silica and alumina for the pozzolanic reaction. The aggregate including natural stone aggregate or non-hazardous industrial waste adds structure strength and bulk to the final mix.
The process of creating a stabilized road base using an aggregate including non-hazardous industrial waste and oil and gas waste material may incorporate a water based chemical agent such as waste cement, varying amounts of aggregate and waste to produce a cold mix, stabilized road base product. An aggregate crusher may process the inert material (typically aggregate including the non-hazardous industrial waste or natural stone aggregate), into the size and texture required (from, for example ½″ to 4″). The aggregate is added to the treated oil and gas waste material at a desired ratio. It has been found that an approximate ratio of one-to-one treated oil and gas waste material to aggregate provides a good mix. This could vary depending upon the degree of contamination or the quality of the oil and gas waste. A chemical reagent is added to congeal the mixture. An asphalt emulsifier is added to create an asphalt stabilized road base. The resulting product is a stabilized road base that not only is of a superior grade, but will not leach hydrocarbons, chlorides or RCRA metals in excess of constituent standards set forth in the Clean Water Act.
In order to further the environmental objectives of the present invention, it is desirable to isolate the oil and gas waste material from the environment prior to mixing. Thus, while the aggregate may be stored on the ground, oil and gas waste material should be stored surrounded by a berm and/or placed on a cement pad, or otherwise isolated by a physical barrier that will prevent leaching of liquid contaminates into the soil. This also prevents storm water runoff. The manufactured road base typically is mixed, processed, and likewise stored surrounded by an earthen berm and on a cement pad and/or other physical barrier that will prevent leaching of liquid contaminates into the soil. Thus, the present invention provides a novel method that will produce grade road base material.
Among the objectives of the present invention are to:
a. combine treated oil and gas waste material with aggregate to produce a stabilized road bed composition;
b. reduce waste from oil drilling, and construction/demolition and manufacturing;
c. reduce the use of new materials for roadbeds;
d. provide a method for producing roadbed material at a lower cost than conventional methods;
e. provide methods of treating oil and gas waste material to yield a material that can be used for preparing a stabilized roadbed and also yield clean mud and water;
f. combine treated oil and gas waste material with non-hazardous industrial waste or naturally occurring material to yield an environmentally safe, usable, stabilized road bed composition;
g. provide simple methods of removing a liquid component from oil and gas waste material;
h. recycle aggregate waste from construction, demolition and manufacturing sites; and
i. provide for a single site or location to which oil and gas waste is transported and at which it is treated and mixed to a road base composition.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an overview of a process of storage and treatment by dry mixing the oil and gas waste material.
FIG. 1A is a generalized view of a process of Applicant's present invention.
FIG. 2 is a flow chart illustrating an overview of a process of combining treated oil and gas waste material and aggregate to produce, typically in a pug mill, waste mix 14 , which cures to form a novel road base.
FIGS. 2A-2D illustrate Applicant's novel method and device for stacking oil and gas waste material.
FIGS. 3 and 3A represent preferred alternate embodiments of a process of treating the oil and gas waste material to prepare it for combination with the aggregate waste material.
FIG. 4 shows an alternate preferred embodiment of Applicant's present invention that may be incorporated in whole or in part into previous embodiments of Applicant's present invention.
FIG. 5 illustrates an alternate preferred embodiment of Applicant's present invention that may be incorporated in whole or in part into the embodiments set forth here and above.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1A illustrates an overview of the steps of Applicant's present invention, Applicant provides for, in obtaining step 1 A, obtaining oil and gas waste from an oil and gas waste site as set forth in more detail below and transferring the waste to a treatment and mixing site. The second step, the obtaining step 1 B, is that of obtaining an aggregate, typically inert, from a natural source such as limestone rock, caliche, rip rap, sand, dirt or the like or, as waste material from a construction, manufacturing, or demolition site. Step 2 is the treatment of oil and gas waste to remove fluids and obtain water and recyclable material, which may be further processed. The third step is some form of mixing (as described in more detail below) wherein treated oil and gas waste is combined with aggregate and other material to provide an environmentally safe roadbed.
Turning back to the oil and gas waste, it is typically transported to the treatment site where Applicant's novel treatment provides several methods of removing at least some of the fluids, from the oil and gas waste material to provide a treated oil and gas waste material road base component which then is mixed with the aggregate to form a road base. As is apparent from FIG. 1A , the treatment step, step 2 removes water and also provides for recyclable or reusable material, such as clean mud and oil in step 2 A. Further, it is seen that step 3 , a step of mixing, may include not only the mixing of the aggregate with the treated oil and gas waste, but also mixing in other material such as binder, emulsion, etc., as set forth in more detail below. The result of the novel process is to provide a novel road base composition which is made up of treated oil and gas waste material and an aggregate and to apply such composition to a road base location.
Turning to FIG. 1 , it is seen that, what is received from the oilfield site ( 32 ) at mixing site ( 16 ) is either tank liquids ( 30 A) or truck solids ( 30 B) sometimes called “cuttings”. We will call these materials collectively oil and gas waste material ( 10 A). Upon arrival at mixing site ( 16 ), tank liquids ( 30 A) may be deposited into a leak proof liquid storage tank ( 11 ). Truck solids ( 30 B), which have a more solid like consistency than the tank liquids ( 30 A), may be deposited on an impervious layer ( 19 ) and contained, typically, in a earthen storage berm ( 13 ). FIG. 1 shows that tank liquids ( 30 A) and truck solids ( 30 B), collectively referred to as oil and gas waste material ( 10 A) is obtained from an oilfield site ( 32 ) including but not limited to drilling sites, pit clean-up sites, spill clean-up sites, blow-out sites and oil and gas exploration, pipelines and refining industry or production sites. Typically the oil and gas waste material ( 10 A) will be either “liquids” transported away from the oilfield site ( 32 ) in vacuum trucks or waste of a more “solid” or “slurry” consistency and transported in dump trucks. The oil and gas waste material ( 10 A) is transported from the oilfield site ( 32 ) to a mixing site ( 16 ) by a first transport such as by a vacuum truck for liquids (“tank liquids”) ( 30 A) or a second transport such as a dump truck for the “slurries” (“truck solids”) 30 B. FIG. 1 illustrates the dry mixing method of treatment; truck solids ( 30 B) may be combined with soil ( 15 ) or other dry, absorptive indigenous material to help dry them and then stored on an impervious layer ( 19 ) as dried truck solids ( 17 ) in a storage pile ( 19 A) on an impervious layer ( 19 ). The impervious layers disclosed herein are man-made, as from concrete, plastic, steel, the road base material described herein or the like. Indeed, all of the storage and treatment of the oil and gas waste material ( 10 A) may take place in an enlarged enclosure the bottom of which has an impervious layer ( 19 ) and optionally, sides of which include a storage beam ( 13 ) made of either concrete or some other suitable material.
The next step in handling the oil and gas waste material ( 10 A) is to treat it to at least remove some of the liquids therefrom (typically oil and water) so as to prepare a treated oil and gas waste/road base component material ( 29 ) for mixing in the pug mill ( 18 ) to produce road base ( 20 ). Applicant provides a number of processes to treat the oil and gas waste material ( 10 A). These processes include “dry mixing” as illustrated in FIG. 1 , “stacking” as illustrated in FIG. 2B and “mechanical separation” as illustrated in FIGS. 3 and 3A . FIG. 1 illustrates a treatment of oil and gas waste material 10 A.
Turning to FIGS. 2A-2D , Applicant's treatment by stacking is illustrated. In this preferred embodiment of treatment of oil and gas waste by way of a draining/evaporation process, the draining induced by gravity and the weight of the waste material itself is used along with a unique apparatus including a drainage assembly ( 60 ) to help remove oil and other liquids from either the truck solids ( 30 B) or a mixture of truck solids ( 30 B) and tank liquids ( 30 A). It is pointed out here that it is preferable that the oil and gas waste material ( 10 A) be treated to remove some of the liquids as it then makes the mixing of the road bed composition more effective. Typically, when the treated oil and gas waste material ( 10 A) is paint filter dry or thereabout, it is sufficiently dry or damp to be processed in the pug mill. Moreover, it is not necessary for all the fluids to be removed from the oil and gas waste material ( 10 A) which may in fact, be somewhat damp after treatment.
Turning back to FIG. 2A it is seen that the stacking step ( 28 A) includes a step of providing a drainage assembly ( 60 ) which includes a screened enclosure ( 62 ) typically three-sided and contained within the an impervious enclosure ( 64 ). More specifically, drainage assembly ( 60 ) is designed to contain within impervious enclosure ( 64 ) the screen enclosure ( 62 ) which is usually constructed from rigid frame member ( 62 A) consisting of angle iron welded or bolted together, which frame members secure screened walls ( 62 B), which screened walls may be made from a suitable screening material or expanded metal, with holes, typically in the range of sixty mesh to ¼ inch. The screened enclosure ( 62 ) is located in an impervious enclosure ( 64 ), which impervious enclosure includes a bottom wall ( 64 A) and a side wall portion ( 64 B). It is seen that the dimensions of the screen enclosure ( 62 ) are such that there is a gap created between screened wall ( 62 B) and side wall ( 64 B) of the impervious enclosure ( 64 ). It is in the gap ( 65 ) created by the dimensions of the screened enclosure ( 62 ) and impervious enclosure ( 64 ) respectively, that drainings ( 71 ), that is liquids comprising typically oil or some water, collect. Within screened enclosure ( 62 ) and typically piled such that its vertical height exceeds the length or width of the screened enclosure ( 62 ) is stacked oil and gas waste ( 59 ) which is comprised of either truck solids ( 30 B) or a combination of truck solids ( 30 B) and tank liquids ( 30 A). Stacking the stacked oil and gas waste ( 59 ) in a manner so that is has a substantial vertical dimension (height) helps to ensure that there is sufficient weight to squeeze out drainings ( 71 ), which may be then evacuated either continuously or periodically from gap ( 65 ) through the use of a pumping or vacuum system ( 66 ). The pumping system includes pump ( 66 A) and an engaging tube or hose ( 66 B) or a vacuum hose attached to a vacuum truck (not shown). Tube or hose ( 66 B) has a first end for immersion in the drainings ( 71 ) and a removed end outside impervious enclosure for transporting drainings to a desired site. Pump ( 66 A) may be electric or hydraulic or any other suitable means and may be float controlled for it to be activated when draining ( 71 ) reaches sufficient depth within impervious enclosure ( 64 ).
An alternate preferred embodiment of Applicant's drainage assembly ( 60 ) there may be troughs or grooves ( 65 ) provided in the bottom wall ( 64 A) of impervious enclosure ( 64 ) to assist in the draining of the stacked oil and gas waste ( 59 ) (See FIG. 2B ).
The drainage assembly ( 60 ) may be any size, but is preferably designed to contain from 1 yard to 300,000 yards of stacked oil and gas waste ( 59 ) which may be dumped into the screened enclosure ( 62 ) using a front end loader or by dump truck or vacuum truck. They may be left to allow for the draining anywhere from a day to ten days or longer depending upon how saturated they are at the beginning of the treatment process. They are then removed from the screened enclosure ( 62 ) by any suitable method and are then typically ready for transport to the pug mill for mixing.
FIGS. 2C and 2D are views of an alternate preferred embodiment of Applicant's drainage assembly ( 80 ). This embodiment differs from the embodiment illustrated in FIGS. 2A and 2B in several respects. First, the stacked oil and gas waste ( 59 ) is enclosed in a three-sided or walled mesh enclosure ( 82 ). That is, drainage assembly ( 80 ) includes a three-walled mesh enclosure ( 82 ) that consists of a side wall ( 82 A), a back wall ( 82 B) and a second side wall ( 82 C), opposite side wall ( 82 A). The three-walled mesh enclosure has an open front ( 82 D). The mesh enclosure ( 82 ) lies within concrete retainer shell ( 86 ) or impervious layer and slightly spaced apart therefor to create a gap ( 65 ). Retainer shell ( 86 ), typically made from concrete and about three feet high, has typically three walls: side wall ( 86 A), back wall ( 86 B), second side wall ( 86 C), the second side wall being opposite the first side wall. The retainer shell has an open front ( 86 D) to allow dump trucks to back in and dump their load of oil and gas waste. A floor ( 86 E), typically concrete, is provided.
The retainer shell is typically about 100 feet by 100 feet with the back and two side walls about three feet high. Further, the floor is typically slanted a few degrees from horizontal dipping towards the back wall to allow liquids to drain to the back rather than out the open front.
Mesh or screen sections ( 84 ) typically come in 4-foot by 8-foot sections and can be laid lengthwise inside the side and back walls of the impervious enclosure spaced apart therefrom by the use of steel braces ( 88 ) set vertically on the floor and typically having a length of about four feet (representing the height of the 4′×8′ sections) which lay on the concrete floor. The braces will prevent the mesh or screen ( 84 ) from collapsing from the weight of the oil and gas waste material stacked against it and the braces provide for a gap ( 65 ), usually about six inches or so, from which a pump or vacuum system and related plumbing may be provided to remove liquids accumulating therein. It is seen that across the top of the beams enjoining a top perimeter of the wire or mesh section is a closed top ( 90 ) typically with an access door ( 90 A). The function of the closed top is to prevent any oil and gas waste material stacked too high from falling over the top perimeter of the mesh section into the gap between the mesh section and the concrete wall. The access door may be opened to periodically insert a hose or pipe to evacuate accumulated liquids from gap ( 65 ). It is noted with reference to FIG. 2D that mesh typically stands a bit higher than the top of the three walls of the retainer shell. The space between the top of the impervious layer and the closed top ( 90 ) may be left open or closed with a suitable member. Closing that area would of course prevent accidental spillage of material into gap ( 65 ).
The material that accumulates in the gap is oil with some water and may be sent to the mud tank or used to add to clean mud. It further may be separated, having an oil component and a water component with the water component disposed of, and the oil component used to add to the clean mud.
As is illustrated in FIG. 2 , the oil and gas waste treatment ( 28 ) may also treat the oil and gas waste ( 10 A) to remove a clean mud component ( 23 ), and a water component ( 25 ), yielding treated oil and gas waste/road base component material ( 29 ). Such treated oil and gas waste/road base component material ( 29 ) may then be combined with stone ( 42 ), “sized” stone ( 44 ), non-hazardous industrial waste ( 12 ), or “sized” non-hazardous industrial waste ( 37 ) or a combination of the preceding. These may be combined directly with the treated oil and gas waste/road base component material ( 29 ) in a pug mill ( 18 ) or other suitable mixer or may be combined to form a pre-mix ( 31 ), which is then deposited into a pug mill ( 18 ) for further combining the two components together and for adding such as portland cement ( 22 ) and a binder such as asphalt emulsion ( 24 ) to yield, upon curing, the stabilized road base ( 20 ) (water may be added as necessary).
The second of the two primary components of the stabilized road base ( 20 ) is an aggregate component ( 61 ) which is collectively either stone ( 42 ) (naturally occurring) and/or non-hazardous industrial waste ( 12 ). This non-hazardous industrial waste ( 12 ) typically consists of inert aggregate material, like broken up brick or cinderblock, broken stone, concrete, cement, building blocks, road way, and the non-metallic and non-organic waste from construction and demolitions site.
Non-hazardous waste ( 12 ) can be obtained from many sources and have many compositions. It includes waste brick materials from manufacturers, waste cement or other aggregate solid debris of other aggregate from construction sites, and used cement and, cement and brick from building or highway demolition sites.
Aggregate sites ( 34 ) include construction sites, building and highway demolition sites and brick and cement block manufacturing plants quarries, sand, dirt, or overburden or caliche pits. The aggregate is transported by dump trucks or the like to mixing site ( 16 ) where it may be separated down to a smaller size, that is, into aggregate particles typically less than 1½″ in diameter by running them through a screen ( 33 ). Any material that is left on top of the screen may go to a crusher ( 35 ). That material may go back to the screen ( 33 ) until, falling through the bottom of the screen and measuring less than about 1½″ in size. This will result in what is referred to as “sized” aggregate ( 30 ). This sized aggregate ( 30 ) is the aggregate component of the stabilized road base ( 20 ). It may then be combined with the treated oil and gas waste/road base component material ( 29 ) in a pre-mix ( 31 ) as by using backhoes or loaders to scoop treated oil and gas waste/road base component material ( 29 ) to physically mix with sized aggregate ( 30 ) (or unsized aggregate) to create a pile or batch of pre-mix ( 31 ), which then can be added to the pug mill ( 18 ). Optionally, this premix ( 31 ), if it has sufficient dampness from residual oil and moisture, may be combined with sufficient portland cement ( 22 ) to coat the particles, before putting it into the pug mill ( 18 ). As set forth above, treated oil and gas waste/road base component material ( 29 ) may be deposited directly into the pug mill ( 18 ) and sized aggregate ( 30 ) can be separately dumped into the pug mill ( 18 ) and the material mixed directly without a pre-mix ( 31 ). Note that portland cement ( 22 ) and asphalt emulsion ( 24 ) may also be added to the pug mill ( 18 ) while the two primary components, treated oil and gas waste/road base component material ( 29 ) and aggregate are being mixed. Typically, the treated oil and gas waste/road base component material ( 29 ) and aggregate ( 30 ) are mixed in a ratio of about 50/50, but may be between 20/80 and 80/20. After the material is thoroughly mixed in the pug mill ( 18 ), it is deposited on the ground and may be contained by a berm ( 13 ) on a impervious layer ( 19 ) for curing (typically for about 48 hours). At this point, leach testing ( 40 ) can also be performed to determine whether or not the ratios of any of the materials need to be adjusted. Leach testing is usually done at a lab to ensure that materials from the road base do not leach into the ground.
The oil and gas waste material ( 10 A) is comprised of hazardous and non-hazardous hydrocarbon based discarded material by oil and gas exploration production, transportation, and refining industries. Oil and gas waste material may include water base drilling fluid, drill cuttings, waste material from produced water collecting pits, produced formation sand, oil based drilling mud and associated drill cuttings, soil impacted by crude oil, dehydrated drilling mud, oil, pipelines and refining industries and like waste materials. It may be “dried” by one or more of the novel drying processes disclosed herein. The term oil and gas waste material as used herein is not intended to be limited by definitions found in various codes or statutes.
Typically the oil and gas waste material ( 10 A) contains enough liquids such that the aggregate ( 61 ) will likely become saturated if a mix is prepared without removal of some liquids, Therefore, the oil and gas waste treatment ( 28 ) of the tank liquids ( 30 A) or truck solids ( 30 B) is usually required. Oil and gas waste treatment ( 28 ) may also be used when clean mud is desired, since clean mud is often readily saleable. The oil and gas waste treatment ( 28 ) results in the production of clean oil and gas waste/road base component material ( 29 ) from the oil and gas waste material ( 10 A).
The term “dry” is relative and means less liquid than before oil and gas waste treatment ( 28 ), typically, resulting in the loss of sufficient liquid such that mixing with the aggregate ( 61 ) will not result in saturation of the combination. If an oil and gas waste treatment ( 28 ) is used, then the treated oil and gas waste/road base component material ( 29 ) are mixed with the aggregate ( 61 ) and portland cement ( 22 ) and emulsion ( 24 ) in a ratio that results in a stabilized product. That ratio is determined by testing leachability of the roadbase for Benzene and RCRA metals; also for strength by testing for compressive strength and vheem stability, pH and chlorides. The ratio may be between 20/80 and 80/20, typically about 50/50. Whether oil and gas waste material ( 10 A) is mixed with aggregate ( 61 ) directly in a dry mix ( 17 ), or if oil and gas waste ( 10 A) is subjected to oil and gas waste mechanical or stacking treatment and treated oil and gas waste/road base component material ( 29 ) are mixed with aggregate ( 61 ), an oil/aggregate mix ( 14 ) results from by the combination.
Typically, aggregate ( 61 ) is optimally sized to ¾ inch to 1½ inch diameter pieces but may include a substantial portion smaller than ¾″. Therefore, a determination of desired size is made and, if the aggregate waste is in pieces that are determined to be too large, they may be crushed in a crushing process ( 35 ) such as by a jaw crusher, to obtain the desired size prior to being added to the treated oil and gas waste/road base component material ( 29 ).
It has been found that a pug mill ( 18 ) provides adequate characteristics for proper mixing. The characteristics of a good mixer are consistency, coatability and durability. An emulsion ( 24 ) is added to the oil/aggregate waste mix ( 14 ) in the pug mill ( 18 ). The emulsion ( 24 ) serves to hold or bind the treated oil and gas waste/road base component material ( 29 ) to the aggregate waste ( 12 ) when the components are mixed and cured. The stabilizer ( 22 ) is, typically, comprised of portland cement. A binder ( 24 ) is also provided, typically asphalt emulsion. While the portland cement and asphalt emulsion can be added in desired quantities, it has been found that portland cement added in range of ½-10% of the final product weight and asphalt emulsion added in range of ½-10% of the final product weight provides good characteristics for the finished product. The oil/aggregate waste mix ( 14 ), binder ( 24 ), and stabilizer ( 22 ) are mixed and cured and the final product, stabilized road base ( 20 ) as determined by compressive strength testing and leachate testing results. Portland cement and asphalt emulsion are added to the waste mix ( 14 ) and mixed into the pug mill ( 18 ) or may be added separately to the pug mill ( 18 ). Optionally, treated oil and gas waste/road base component material ( 29 ) which is sometimes damp, may be coated with portland cement before it goes into the pug mill ( 18 ). The pug mill mixing ( 18 ) is a cold batch process.
More details of Applicant's oil and gas waste material treatment ( 28 ) are provided for in FIGS. 3 and 3A . It will first be noted that one of the purposes of treating oil and gas waste material ( 10 A) may be to derive from it clean mud ( 23 ) which can be sold to oil and gas operators. Secondly, water is taken out of the oil and gas waste materials to be reinjected or otherwise disposed of. Finally, the majority of the oil and gas waste material ( 10 A), upon treatment, will result in treated oil and gas waste/road base component material ( 29 ), that is, oil and gas waste material ( 10 A) from which at least some liquids have been removed.
Turning now to FIGS. 3 and 3A , it is seen that tank liquids ( 30 A) and tank solids ( 30 B) may be treated differently to achieve the removal of a liquid component and for the purposes of obtaining clean mud. Turning to FIG. 3A , it is seen that tank liquids ( 30 A) are typically stored in tank liquid storage ( 11 ) from which they may be piped to and deposited on the top of a fine shaker ( 41 ) which will typically remove off the top thereof a damp solids component ( 63 ). However, a substantial portion of the tank liquids ( 30 A) will work through the fine shaker ( 41 ) into a mud tank ( 43 ) typically located just below the fine shaker ( 41 ). From the mud tank, the fluid will enter a centrifuge ( 46 ) which will separate out another damp solids component ( 65 ) and send a fluid component to a 3 phase centrifuge ( 51 ). From the 3 phase centrifuge will come an additional damp solids component ( 67 ), clean mud ( 23 ) and water ( 25 ).
Turning now to the truck solids ( 30 B), they may be stored “unmixed” ( 16 ) or in a storage pile of dried truck solids ( 17 ) (see FIG. 1 ). Either way, truck solids ( 30 B) may be deposited, typically using a backhoe (or front loader) and a hopper and a conveyor belt onto a coarse shaker ( 45 ) off the top of which come particles which will be a course component ( 69 ). Much of the truck solids ( 30 B) will, however, fall through the coarse shaker ( 45 ) and these are transported or dropped into a centrifugal drier ( 47 ). The centrifugal drier ( 47 ) will yield a treated oil and gas waste/road base component material ( 29 C) and a liquid portion ( 49 ) which will be transported to mud tank ( 43 ) (see FIG. 3A for processing).
Thus it is seen that both tank liquids ( 30 A) and truck solids ( 30 B) coming from oil and gas waste material sites ( 32 ) will undergo some physical separation of some solids from liquids, the liquid portion of which will typically end up in mud tank ( 43 ). The liquids in mud tank ( 43 ) will undergo a process that yields a treated oil and gas waste material/road base component material ( 29 ) and also clean mud ( 23 ) and water ( 25 ).
Novelty is achieved in taking oil and gas waste material including tank liquids and truck solids and making a road base that meets industry standards and is environmentally safe. From the solids a liquid is extracted by stacking, dry mixing or mechanical separation. From the tank liquids a solid portion and a clean mud portion and water is produced (see FIGS. 3 and 3A ). Depending on weather, type of or source of waste material, extent of drying desired, economic consideration, environmental consideration may dictate which of the three types, or combination of the three types will be used.
The oil and gas waste material that is treated according to Applicant's present invention usually contains a solid phase and a liquid phase. It is Applicant's novel methods of treatment that help remove a part of the liquid phase. The following areas list of some of the oil and gas waste material that may be subject to Applicant's novel treatment and use and Applicant's novel roadbase:
Basic sediment and water (BS&W) and tank bottoms; Condensate; Deposits removed from piping and equipment prior to transportation (i.e., pipe scale hydrocarbon solids, hydrates and other deposits); Drilling fluids and cuttings from offshore operations disposed of onshore; Hydrogen sulfide scrubber liquid and sludge; Liquid and solid wastes generated by crude oil and tank bottom reclaimers; Weathered oil; Pigging wastes from producer operated gathering lines; Pit sledges and contaminated bottoms from storage or disposal of exempt wastes; Produced sand; Produced water constituents removed before disposal (injection or other disposal); Slop oil (waste crude oil from primary field operations and production); Crude oil contaminated soil; Tank bottoms and basic sediments and water (BS&W) from: storage facilities that hold product, exempt and non-exempt waste (included accumulated material such as hydrocarbons, solids, sands and emulsion from production separators, fluid treating vessels, production and refining impoundments); Work over wastes (i.e., blowdown, swabbing and balling wastes); Unused methanol; Used equipment lubricating oil; Paint and paint wastes; Pipe dope (unused), Refinery wastes (e.g. tank bottoms); Compressor oil and blowdown wastes; Unused drilling fluids; Chemical contaminated soil; Lube oil contaminated soil; Spent solvents, including wastes solvents; Hydraulic fluids (contaminated); Waste in transportation pipeline related pits, Cement slurry returns from the well and cement cuttings; Produced water—contaminated soils; and PCB (polychlorinated biphynols) contaminated soils.
The attached FIGS. 4 and 5 illustrate at least part of an alternate preferred method for treatment of oil and gas, and more specifically for the treatment of drilling waste. Drilling waste is intended to identify waste more specifically than oil and gas waste. That is, drilling waste is waste material directly associated with the drilling of a well. Drilling waste is typically in the nature of: drill cuttings, drilling mud, and clean up material from a drilling location. Applicant has found that the method set forth herein and hereinabove may be advantageously and more specifically directed to drilling waste, accumulated from offsite and shipped to Applicant's site for processing and combined with aggregate, the aggregate also typically trucked in from offsite. In this manner, drilling waste may be effectively combined with an aggregate to form an environmentally safe road base capable of passing most governmental agency standards and engineered to pass tests to determine its structural soundness.
The roadbase compositions prepared by the methods set forth in FIGS. 4 and 5 may be mixed in accordance with the recipes set forth hereinabove, with asphalt emulsion as an optional additive. Further, while the methods, devices and compositions set forth in these specifications are satisfactory with most oil and gas waste as set forth herein, drilling wastes are favorably disposed of and converted herein to an environmentally compatible and soundly engineered road base.
In FIGS. 4 and 5 , methods and devices are provided that will assist in efficiently handling oil and gas waste, but more specifically drilling waste. It will be noticed with reference to the figures that Applicant may utilize a conveyor system which may be screw or auger conveyors (or belt conveyors, pneumatic pressure feed, or direct feed with heavy equipment) for the transport of materials, from any one location to any other location, in applying the method of Applicant's present invention.
Turning now to FIG. 4 , Applicant discloses a pile of, typically, stacked aggregate ( 61 ), brought to Applicant's site from, typically, an offsite location. Applicant also discloses a pile, typically stacked, of drilling waste ( 101 ). This drilling waste originated offsite, being transported to Applicant's facility typically by trucks and/or barges and the like. The material ( 61 / 101 ) is typically underlain by an impervious layer and may or may not include a berm. Excavators ( 105 ), or backhoes or the like with front-end loaders attached thereto may scoop and transport material ( 61 / 101 ) to a screen shaker ( 108 ) for separation of large chunks of material, typically greater than about 3 to 4 inches in their narrowest dimension from the mix that will then directly enter pugmill or other mixer ( 112 ). Optionally, excavators ( 105 ) may load aggregate ( 61 ) and/or drilling waste ( 103 ) onto a screen and/or shaker ( 108 ) with the droppings going into a screw auger ( 104 , 106 ), which typically contains a hopper ( 104 A, 105 A) thereon for transportation to the mixer.
In the alternative, pugmill ( 112 ) may be placed directly beneath shaker ( 108 ) with the shaker loaded by heavy equipment or a conveyor. Screw conveyor ( 114 ) having a hopper ( 114 A) thereon may be placed beneath or adjacent pugmill ( 112 ) for transporting the mixed material, now road base material, to a stacking location typically underlain by an impervious layer, here seen as road base material ( 20 ). In the alternative, the pugmill can dump its contents directly on the ground.
Thus, it is seen that Applicant has provided for the transportation of materials through the use of a conveyor system and has, further, provided for the introduction of drilling waste on the one hand and aggregate ( 61 ) on the other, either contemporaneously or sequentially into a screen shaker for initial separation followed by conveyance to a pugmill. It is noted that, optionally, liquids may be removed from drilling waste material ( 101 ) before movement to the shaker screen and pugmill according to FIG. 4 . It is to be understood that the same screw conveyor (or belt conveyor, pneumatic conveyor, or direct feed) may be used to first take one of the aggregate or drilling waste to the pugmill then the other. Wherever either of these materials need to be conveyed from its storage point to the pugmill and/or shaker, any one of: a screw conveyor, a belt conveyor, a pneumatic pipe/air pressurized delivery system, or direct feed (heavy equipment) may be used.
FIG. 5 illustrates the use of yet another screw conveyor ( 116 ). Here, Applicant has found it effective to combine liquids received as drilling waste, typically held in a container or tank ( 103 ), with drilling waste material that is received in trucks and is typically drier, here drilling waste material ( 101 ) (typically stored on an impermeable pad). An excavator ( 105 ) may be used to load a hopper of screw conveyer ( 116 ), creating a stackable mass ( 111 ) of waste material, comprising liquid components of drilling waste and solid stackable components of drilling waste material ( 101 ) thereof. An excavator or loader and a screw conveyor may be used to form a stackable mass ( 111 ) of drilling waste. This drilling waste may be further processed according to methods and with equipment set forth herein to produce an environmentally compatible effective road base material according to the method set forth herein.
It is noted that the use of the screw conveyors, conveyor belts, pneumatic delivery systems and/or direct feed by heavy equipment, may allow effective transportation of material from one point to another at Applicant's facility regardless of the liquid hydrocarbon component thereof and even in inclement weather. The use of a screw auger allows some mixing during the transportation process, therefore further effectuating, such as set forth in FIG. 5 , the creation of a stackable waste material that still has a liquid component typically not, however, to the point of saturation.
With respect to FIG. 5 , it is seen that liquids from drilling waste materials are brought from offsite locations by vacuum trucks and/or barges. Typically, however, waste material ( 101 ) as identified in FIG. 5 from drilling sites is typically brought in via dump truck and simply dumped on the impervious pad.
Further, Applicant has found through testing that a particular type of centrifuge works best for the drilling mud production process set forth herein (see FIG. 2 ). These specifications of the centrifuge are as follows: Three phase, with an external adjustable skimmer. One such three phase centrifuge is available from Flotwig.
Applicant provides a conveyor system for movement of drilling waste and/or aggregate about Applicant's treatment site. The conveyor system may be one or more: belt conveyors; screw conveyors; pneumatic pressure feed conveyors, or direct feed (that is by heavy equipment such as front-end loaders). Optionally, a screen or shaker may be used at any point in the conveying system where it desired to remove larger chunks from entry into either belt conveyor or screw conveyor or the pugmill. Further, while aggregate is typically transported from offsite, the treatment facility may be built on a site where aggregate is readily available, such as a caliche pit.
Although the invention has been described with reference to specific embodiments, this description is not meant to be construed in a limited sense. Various modifications of the disclosed embodiments, as well as alternative embodiments of the inventions will become apparent to persons skilled in the art upon the reference to the description of the invention. It is, therefore, contemplated that the appended claims will cover such modifications that fall within the scope of the invention. | The present invention provides a novel method to produce grade road base material using recycled oilfield waste, called “oil and gas waste,” more specifically, drilling waste and aggregate and a novel road base material. Hydration and mixing of the waste materials along with a binder, will achieve an irreversible pozzolanic chemical reaction necessary for stabilization into a road base. An asphalt emulsifier may be included in the binder to manufacture asphalt stabilized road base. The entire method is a cold batch process. | 2 |
RELATED APPLICATIONS
[0001] This application is a continuation-in-part of co-pending U.S. patent application Ser. No. 10/902,631 filed Jul. 28, 2004 which claims priority to U.S. Provisional Application No. 60/490,607 filed on Jul. 28, 2003.
FIELD OF THE INVENTION
[0002] The invention relates a shaped gasket generally used in association with a cap to seal vessels, drums, casks, barrels or containers for containing liquid, or other applications where and air or liquid tight seal are required. An example of such a container is a 55 gallon drum having an aperture in its lid, the aperture being adapted to receive the cap and gasket, the gasket forming an air or watertight seal.
SUMMARY OF THE INVENTION
[0003] The disclosure herein is for a gasket or seal generally used with a screwcap. A typical application is the screw plug found in 55 gallon drums used for containing liquids. However, one skilled in the art will recognize that the gasket profiles described and claimed herein have applications in other apparatus where an air or watertight seal is desired, and need not be limited to annular gaskets .
[0004] The threaded cap and gasket shown herein is generally used for 55 gallon storage drums, and is screwed into a threaded hole or aperture in the drum. The threaded aperture is often times formed by inserting a flanged receiver into the lid or side wall of the drum. The flanged portion remains outside of the drum, with a cylindrical portion bearing the threads extending into the interior of the drum. The flanged portion then forms a bearing or sealing surface for the gasket when the cap is screwed in to the threaded aperture.
[0005] One skilled in the art will recognize that other types of securing structure could be used to secure the cap instead of threads. For example, the cap could be secured by friction fit, bayonet mount, or other mechanisms known for securing a cap or plug into an aperture. In any instance, the shaped gasket is included to form a water or air tight seal between the cap and a bearing surface surrounding the aperture.
[0006] The gaskets shape includes a portion that contacts the cap, and distended wing portions that form a profile wider than the portion of contact with the cap. The portion of the gasket between the distended portions is generally concave, so as to form two areas of initial contact with the opposing sealing surface. In some embodiments, the sealing surface may be shaped to provide a convex surface opposing the concave surface of the gasket. The gasket may be made of any material commonly used for gaskets, such as rubber, nylon, silicone, urethane, neoprene, polypropylene, polyethylene, or any other pliable material used in the gasket industry. The gasket may be made of the same material as the cap, and be formed as a unitary structure with the cap. Additionally, the gasket may be attached to the cap by a co-molding process, where the gasket and cap may or may not e constructed of the same material.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 is a cross sectional view of a threaded cap and shaped gasket.
[0008] FIG. 2 is a cross-sectional view of the preferred embodiment of the gasket profile.
[0009] FIG. 3 is a cross-sectional view of an alternate embodiment of the gasket profile.
[0010] FIG. 4 is a cross-sectional view of an alternate embodiment of the gasket profile.
[0011] FIG. 5 is a cross-sectional view of an alternate embodiment of the gasket profile.
[0012] FIG. 6 is a cross-sectional view of an alternate embodiment of the gasket profile.
[0013] FIG. 7 is a cross-sectional view of an alternate embodiment of the gasket profile.
[0014] FIG. 8 is a cross-sectional view of an alternate embodiment of the gasket profile.
[0015] FIG. 9 is a cross-sectional view of an alternate embodiment of the gasket profile.
[0016] FIG. 10 is a cross-sectional view of a further alternate embodiment of the gasket profile.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0017] With reference to FIGS. 1 and 1 A, a threaded cap 10 and gasket or seal 20 are shown in association with a threaded receiver 30 inserted into an aperture, such as would be used in the lid 35 of a 55 gallon drum or other container. The cap 10 includes a top portion 9 and a cylindrical portion 8 having threads. The receiver 30 includes a cylindrical portion 31 and a flange 33 , the cylindrical portion 31 of the receiver adapted to receive the cylindrical portion 8 of the cap 10 , allowing the cap 10 to be screwed into the receiver. In general, the underside 11 of the cap 10 is parallel to the flange 33 , but such a relationship is not necessary. The flange 33 extends about the perimeter of the aperture a sufficient distance so as to form a sealing or bearing surface 34 for the gasket or seal 20 , positioned on the underside 11 of the cap 10 . In an alternate embodiment, the gasket or seal 20 bears upon the lid 35 of the drum. One skilled in the art will recognize the bearing surface 34 can be any structure below the underside 11 of the cap, such that the surface will form a water or airtight seal when the cap 10 is tightened into the receiver 30 .
[0018] The gasket or seal 20 , shown in profile in the drawings, is annular and extends around the cap 10 . Although the gasket can touch both the cylindrical portion 8 and the top 9 of the cap 10 , the gasket 20 can also be sized or positioned so that it does not contact the cylindrical portion 8 of the cap 10 . In the preferred embodiment, the gasket or seal 20 has a zone of contact or attachment 21 that contacts the underside 11 of the cap 10 . The zone of contact 21 may be attached to the cap 10 by a suitable adhesive, bonding, or other means of attachment such as co-molding, or it may be un-adhered and simply be in contact with the cap 10 at the zone of contact 21 . In an alternate embodiment, the gasket 20 and cap 10 are made as a unitary structure, the zone of contact 21 in such an embodiment being defined as the same area of the structure as if the gasket were adhered to the underside 11 of the cap 10 .
[0019] In the preferred embodiment, the zone of contact or attachment 21 of the gasket 20 is generally flat, as shown in the figures, or corresponds to the shape or surface to which it is contacting. For instance, if the underside 11 of the cap 10 had grooves, it is contemplated that the gasket 20 will have corresponding grooves on the zone of contact or attachment 21 . Such correspondence however, is not necessary.
[0020] As shown in FIGS. 1, 2 , 3 , 7 , 8 , and 9 , the seal 20 has distending winged portions 22 and 23 that extend away from the zone of contact or attachment 21 . Thus, it is preferred that the widest portion of the gasket, in this instance the distending winged portions 22 and 23 , is wider than the zone of contact 21 . The seal 20 forms a generally concave shape between the ends 40 and 41 of the winged portions 22 and 23 . Within these general parameters, it is recognized that the seal 20 may take different shapes in cross-section or profile, as exemplified in FIGS. 2 through 9 . Further, it is not required that each of the winged portions be of the same shape.
[0021] In operation, as the cap 10 is screwed into the receiver 30 , the winged portions 22 and 23 of the seal 20 contact a surface to achieve closure or a water or air tight seal. In the preferred embodiment, the seal is positioned around the cap 10 so that the winged portions 22 and 23 contact the receiver flange 33 , barrel lid 35 , or other bearing or sealing surface 34 .
[0022] In alternate embodiments, as shown in FIGS. 4, 5 and 6 , the winged portions 22 and 23 extend no wider than the zone of contact or attachment 21 . As the cap 10 is screwed into the receiver 30 , the seal or gasket 20 is compressed between the underside 11 of the cap 10 and the bearing surface 34 . When compressed, the winged portions 22 and 23 of the seal or gasket 20 can extend beyond the width of the zone of contact or attachment 21 .
[0023] As shown in the figures, the gasket or seal can take on a number of different shapes. One will recognize that the attribute and structures shown in any of the embodiments can be combined with those of the other embodiments to form profiles not shown, but consistent with the claimed invention. For instance, the profile shown in FIG. 1 could include the concave walls 48 and 49 as shown in FIG. 6 .
[0024] As shown in FIG. 2 , the seal 20 includes distending winged portions 22 and 23 that form an angle of approximately 45 degrees with respect to the underside 11 of the cap 10 . The ends 40 and 41 of the winged portions 22 and 23 are generally rounded. Between the ends 40 and 41 , the concave portion 25 is generally rounded as well, although the surface of the seal between the ends need not assume any particular shape, so long as it is concave.
[0025] As shown in FIG. 3 , the seal 20 can include a concave portion 25 that has generally straight walls 44 and 45 that converge at an vertex 26 . Also shown in FIG. 3 , the distending winged portions can exhibit an angle greater than 45 degrees with respect to the underside 11 of the cap 10 . Such an angular arrangement allows for a larger zone of contact or Attachment 21 and increases the seal 20 's resistance to compressive forces, as the cap 10 is screwed into the receiver 30 .
[0026] In the alternate embodiment shown in FIG. 4 , the winged portions form an angle of 90 degrees with the underside 11 of cap 10 . In such an arrangement, the walls 44 and 45 are essentially perpendicular to both the underside 11 of the cap 10 , and the bearing or sealing surface 34 , when the gasket or seal 20 is in an uncompressed state. The alternate embodiment also demonstrates the ends 40 and 41 of the winged portions 22 and 23 can be generally pointed, rather than rounded. The concave portion 25 is formed by straight surfaces 46 and 47 meeting at an vertex 26 . The distance from the vertex 26 to the underside 11 of the cap 10 is approximately one half of the distance from the ends 40 and 41 of the winged portions 22 and 23 to the underside 11 of the cap 10 . Put another way, the concave portion 25 has a maximum depth that is roughly one half of the total height of the seal 20 . The depth of the concave portion can vary from one eighth of the total height of the seal 20 to seven eighths of the maximum height of the seal 20 . In the case of a co-molded cap and gasket, the maximum depth is not applicable, as the division between the cap and gasket is non-existent. In such an embodiment, the maximum depth of the cap can occur at a level above the underside of the cap.
[0027] As shown in FIG. 5 , an alternate embodiment includes winged portions 22 and 23 that do not extend beyond the width of the zone of attachment or contact 21 when the seal 20 is in an uncompressed state. When such a seal 20 is compressed between the underside 11 of the cap 10 and the bearing or sealing surface 34 , the ends 40 and 41 of the winged portions 22 and 23 can extend beyond the width of the zone of attachment 21 .
[0028] As shown in FIG. 6 , the walls 48 and 49 extending from the zone of contact 21 to the ends 40 and 41 of the winged portions 22 and 23 can be concave.
[0029] As shown in FIGS. 7, 8 , and 9 , the seal 20 can be attached to the barrel or flange 33 instead of the cap 10 . In such an arrangement, the underside 11 of the cap 10 becomes the bearing or sealing surface 34 , and the flange 33 bears upon the zone of contact 21 . As shown in FIGS. 8 and 9 , the sealing surface 34 may include a shape 50 protruding therefrom. Put another way, the bearing or sealing surface 34 need not be flat, but may be convex. The sealing surface 34 can also include contours or any shape or profile, including rounded and angular portions. The shape is received by the concave portion 25 of the seal 20 , thereby providing a greater surface area of contact for the seal 20 . The shape 50 need not be of complimentary shape to the concave portion 25 . As shown in FIG. 8 , the shape 50 can be generally rounded, and the concave portion 25 of the seal 20 can be angular, having straight surfaces 46 and 47 . However, in other embodiments, the shape 50 can be complimentary, as shown in FIG. 9 . Such a complimentary arrangement maximizes the contact surface area with the concave portion 25 of the seal 20 .
[0030] A further alternative embodiment is shown in FIG. 10 . Similar to the earlier embodiments of the invention, the gasket or seal 120 , while shown in profile, is annual and extends around the cap. The gasket or seal 20 has a zone of contact or attachment 121 that contacts the underside of the cap in the same fashion as described above. The zone of contact 121 may be where the gasket or seal 120 is attached by any suitable means, such as adhesives, bonding, welding, or any other means of attachment such as co-molding, as appropriate. In an alternative, the gasket or seal 120 can be part of the cap and made as a unitary structure.
[0031] In this form of the invention, the seal 120 has distending winged portions or ribs 122 and 123 that extend away from the zone of contact or attachment 121 . Unlike the earlier forms of the invention, the embodiment shown in FIG. 10 is not symmetrical, in that the winged portion 123 forms an angle 124 with the cap, the angle 124 being different than the angle 125 that the winged portion 122 forms with the cap. Preferably the angle 124 is on the order of 90° while the angle 125 is on the order of 75°. Also as illustrated, the winged portion 123 extends farther away from the cap than the winged portion 122 . Thus, the main seal is the winged portion 123 , with the winged portion 122 forming a secondary seal. Preferably the wings 122 and 123 are formed about a 15° included angle.
[0032] As thus illustrated, the gasket or seal 120 is not symmetrical and provides what is believed to be a superior seal. Also, while the preferred configuration is as illustrated in FIG. 10 , the configuration can be a mirror image of that illustrated, thus with the angle 125 being approximately 90° and the angle 124 being approximately 75°, and the same type of seal will result.
[0033] While the angles 124 and 125 are preferred within the ranges set forth above, there can be variances from those angles and still be within the scope of the invention, so long as there is a difference of about 15° between the angles 124 and 125 .
[0034] The description and drawings of the preferred embodiment are merely illustrated in nature, and the present application includes all other embodiments and equivalents that are within the spirit and scope of the described embodiment. | The invention described herein is a shaped seal or gasket for use with a screw cap as commonly used in chemical barrels. The shaped gasket has a profile that includes a winged portion for contacting a sealing surface. The winged portion of the gasket defines a concave surface. The gasket has a second surface, or zone of contact, for contacting against a second surface, such as the underside of a screw cap. The winged portion of the gasket profile is wider than the zone of contact. The gasket profile can take on many different configurations, as shown in the drawings. | 1 |
TECHNICAL FIELD
[0001] This invention relates to an improved apparatus for installing ceramic tile, brick, block and the like. In particular, the invention relates to a set of installation alignment and spacer tools that allow rapid alignment and proper grout spacing, to enhance the ease of installing tile, and a more consistent, level finished surface to improve the final appearance of newly laid tile.
BACKGROUND ART
[0002] Tile provides not only an especially aesthetically pleasing look, but also a durable surface for a variety of residential and industrial settings. Tile work is generally considered an improvement upgrade to a kitchen, floor, bathroom, and the like, where ceramic tile is installed on the underlayment of either a floor or wall, or both.
[0003] With the strong, present economy, individuals and businesses have generated a greater amount of disposal income that can be put toward general home and business improvements. A vast majority of these improvements comprise an element of new tile work to a kitchen and bathroom, as the walls and floors are reconditioned and upgraded to new ceramic tile surfaces. Even without the present robust economy, there has always been, and will remain, a large amount of ongoing tile work associated with new construction.
[0004] Further, there has also been a concurrent explosion in the construction of home improvement mega-stores which supply the every expanding class of do-it-yourselfers (those finding more pleasure in tackling home and business projects themselves than hiring outside contractors) with the parts and confidence to complete their own improvement jobs. This growth has, in turn, produced a large market of home and business improvement books, Internet services providing step-by-step instructions, and TV shows and video programs for the do-it-yourselfers.
[0005] The present invention provides novel tile installation alignment and spacer tools that are simple enough to be employed by one with little or no skill in laying tile. The present invention is further economically justified for use by experienced contractors since the present invention shaves valuable time off the average professional job, and produces a better aligned tile surface, which can lower the repair cost of mislaid tile.
[0006] In the process of covering floor, wall and counter surfaces with ceramic tile and the like, individual tiles, or sheets of mosaic glued to a mesh webbing, are individually set into either some form of adhesive, or some form of mortar. In the process of setting the individual pieces, it is known to use tile spacers to assist in achieving uniformly sized grout spacing between the tiles or sheets of mosaic. These are typically in the shape of a cross, so as to define a corner where four tiles will intersect. The spacers are typically made of semi-rigid plastic having depths ranging from ⅛ to 3/16 of an inch, with spacing widths of between 1/16 of an inch and ⅜ of an inch. For brick, coment block and larger tiles, larger sizes of spacers, with considerably more depth, are used.
[0007] The spacers are sometimes used edgewise as an aid to laying out an array of tiles where a long row of dry tiles can be laid out, set apart by the edgewise spacers. Such spacers also are sometimes used edgewise as stacking spacers for vertical installations (wall tiles). However, while these smaller T spacer devices work well for tile spacing, they do not do well to set alignment of several tiles (and the like) over a distance. The grout line is therefore not as straight as can be achieved easily with this invention.
[0008] Most tile layers have large, heavily callused fingers and find working with small tools difficult and hard to handle. While working with newer tile spacers is easier, it is difficult and time consuming to handle the large amount of them required for tiling. Additionally, they provide no guide to the proper alignment of the lay of the tiles (the uniformness of the grout line across several tiles) as the job proceeds, or help to assist in leveling the tiles once set.
[0009] To achieve a uniformly straight tiling layout across several tiles, the procedure is to chalk a straight reference line directly onto the prepared under floor. Thin set mortar is then worked up to the line, several tiles are set, and a make shift straight-edge of sorts is placed against the edge of the tiles for final alignment. This process is time consuming and does not allow for the optimum working of the thin set mortar onto the prepared under floor. This invention will substantially reduce the amount of time to achieve final alignment by allowing the tile installer to work more thin set mortar onto the prepared under floor, over a larger area, and directly over a portion of the chalked reference line. In addition, fewer smaller tile spacers will be required.
DISCLOSURE OF INVENTION
[0010] Objects of the invention include provision of tile installation alignment and spacer tools which are easy to handle, which are easily removed after use, which assist in establishing a uniform and straight lay of the tiles, and which will reduce the time to tile.
[0011] According to the present invention, the tile installation alignment and spacer tools include a thin, semi-rigid platform having a varied length straight tile spacer on one side thereof and a handling device (handle) on the other side thereof.
[0012] The platform, which may typically be rectangular, assists in establishing a uniform lay of tiles, and holds a portion of the alignment and spacer tool up above the tiles so it is accessible for removal. The handle on the platform is used principally to handle and manipulate the tool, with the underside protrusion of the tool used to space the intersection of two tiles side-to-side, to align a series of sets of two tiles side-by-side in plane, and to assist in a uniform level of the tiles. The tile installation alignment and spacer tools also serve for vertical tile installations and as ajob layout spacer. The tile installation alignment and spacer tools in accordance with the present invention are easily handled since they can be gripped by the handle when being inserted for use and when being removed. It is also more easily removed once its purpose has been served. It is also intended to be used along with standard use single spacers, albeit with a lesser amount of them now required, which continue to serve for corner (either cross or tee as the case may be), as well as for small and tight straight spaces. The tile installation alignment and spacer tools in accordance with the present invention are scalable to suit a variety of uses, including tile, stone, slate, brick and block, etc.
[0013] Other objects, features and advantages of the present invention will become more apparent in the light of the following detailed description of exemplary embodiments thereof, as illustrated in the accompanying drawing.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 is a top perspective view of the set of tile installation alignment and spacer tools in accordance with the present invention;
[0015] FIG. 2 is a front plan view of the edge of any one of the tools in use and in accordance with the present invention;
[0016] FIG. 3 is a top perspective view of the smallest sized of the tile installation alignment and spacer tools of FIG. 1 in use setting tile;
[0017] FIG. 4 is a top, side, and front plan view of the tile installation alignment and spacer tool of FIG. 3 ;
[0018] FIG. 5 is a more detailed top perspective view of two of the tile installation alignment and spacer tools shown in FIG. 1 ;
[0019] FIG. 6 is a top perspective view of the middle sized tile installation alignment and spacer tool of FIG. 1 in use setting tile;
[0020] FIG. 7 is a top, side, and front plan view of the tile installation alignment and spacer tool of FIG. 6 ;
[0021] FIG. 8 is a top perspective view of the larger sized tile installation alignment and spacer tool of FIG. 1 in use setting tile;
[0022] FIG. 9 is a top, side, and front plan view of the tile installation alignment and spacer tool of FIG. 8 ;
[0023] FIG. 10 is a top perspective view of the larger sized tile installation alignment and spacer tool of FIG. 1 in use to set, space, and align under floor backer board material.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0024] Floor tiles are best centered in the room at a doorway for visual appearance or a prominent window. The center of two opposite walls are first measured, and these points used to snap a chalk line across the length of the room in the center of the floor, dividing the room in half. Another chalk line is snapped perpendicular to the first so the two lines cross in the center of the room. A row of tiles are dry-fit down both lines to the width and length of the room, while leaving a little spacing for the grout joints.
[0025] Once the layout is established, the tile is set. The floor surface must be clean of dust and debris. Concurrently, the tile adhesive only in the amount to be used within 2-3 hours is prepared, which prevents the adhesive from drying out. The full tiles are set first, leaving any cut tiles around the perimeter of the room for last. To install floor tile, the tile is laid from the center of the floor where the two final reference lines cross. A tile at the intersection of the lines is first placed, then, using the lines as a guide, tiles are laid outward toward the walls in each quadrant. The adhesive is spread with the trowel's notched edge, combing it out in beaded ridges. Spaces between ridges of adhesive should be almost bare.
[0026] The first tile in a corner is laid and twisted into the adhesive. About 70-80 percent of the tile backing should be covered with adhesive upon inspection. The remaining tiles are then set aligned to the outside layout lines. Keeping consistent spacing between the tiles is critical for straight, uniform grout lines. Some tiles come pre-mounted on paper grids so the spacing is already established. Once the tiles are in place, they are set into the adhesive so that they are all at the same height.
[0027] After setting all of the full tiles one can measure, cut and set the tile around the edges. If installing a tile floor that runs longer than 24 feet, or if the floor is near an outside wall or exposed to areas that will expand due to temperature and moisture changes, one will need to account for expansion joints. Expansion joints are simply breaks in the tile field that protect and cushion the tile from movements in the underlayment. In most homes, expansion joints can be made by stopping the perimeter tile ¼ inch from the wall.
[0028] Referring to FIGS. 1, 4 , 7 , and 9 , the tile installation alignment and spacer tools 1 , 2 , 3 in accordance with the present invention include a platform portion 8 , 13 , 15 of coplanar, flat surfaces thereof. Elongated, a single raised ridge extends outwardly of the faces of the platform 8 , 13 , 15 to form straight alignment and spacer elements 10 , 14 , 16 extending across the surface 8 , 13 , 15 , respectively. The platform portion 8 , 13 , 15 and ridges 10 , 14 , 16 are all made of a unitary piece of semi-rigid material, such as plastic or metal. In the embodiment disclosed herein, the platform 8 , 13 , 15 is a rectangle of varied lengths 1 . 5 ; 2 . 5 , and 4 . 0 feet, although it need not necessarily be of that exact length. It could be of any length that will provide a platform of reasonable usefulness. Referring also to FIGS. 5, 6 , the straight alignment and spacer elements 10 , 14 , 16 are coaligned with reference line 11 , the edge of the installation alignment and spacer tools 1 , 2 , 3 so as to permit orienting the tools 1 , 2 , 3 to the tiling reference line (blue chalk line) 12 , with respect to the tile being laid, while using the handle 9 to maneuver the tool. For normal tile (such as is used on kitchen counters, bathroom walls, and floors) the tools may have an alignment and spacer element 10 , 14 , 16 just under 7/32 inch in depth and ¼ inch in width. The platform may be about ⅛ inch thick, or it may be thicker, up to about ¼ inch. That is, the grouting width to be achieved and therefore the width of the spacer may range from 1/32 of an inch up to ½ of an inch, or more, and the depth may vary from about ⅛ of an inch to ¼ of an inch, or more, depending upon the desired grout line width and what the tools are to be used for. Of course, much larger tools will be used to handle cement block, glass brick and the like.
[0029] An illustration of the basic idea for a generic view of each tool, 4 , is shown in FIG. 2 . A more descriptive set of illustrations of the typical use of the tools 1 , 2 , 3 of FIG. 1 to line up an orthogonal, symmetrical array of four to ten one foot square standard floor tiles 5 , is shown in FIGS. 3, 6 , 8 . Therein, the tools 1 , 2 , 3 are in the position shown in FIGS. 3, 6 , 8 with the alignment and spacer elements 10 , 14 , 16 facing downward, and the handle 9 used to maneuver the tool. Notice that tools 1 , 2 , 3 not only assist in laying out the spacing between the tiles 5 so as to provide an orthogonal arrangement with uniform grout spaces 7 , but it also establishes a uniform lay (without lippage) by assisting in causing the off-surface displacement of the tips of the tiles 5 to be more nearly uniform: If any of the tiles 5 are not laying flat, the uneven lay of the tool is readily apparent, and the tool can be easily removed so as to correct the lippage or pressure can be applied to the tool, that in turn will provide uniform pressure to level out the tiles.
[0030] The use of the present invention is not limited to tiles alone. FIG. 10 describes the spacing of backerboard material, or any material in fact, that requires uniform spacing. Rather than using nails, as is common, in FIG. 10 the larger length tool 3 is used to space backerboard material 17 to achieve uniform spacing 19 . Naturally the backerboard is secured by screws 18 , or by other means.
[0031] Thus, although the invention has been shown and described with respect to exemplary embodiments thereof, it should be understood by those skilled in the art that the foregoing and various other changes, omissions and additions may be made therein and thereto, without departing from the spirit and scope of the invention. | The present invention overcomes a problem in conventional tile installation by providing tile installation alignment and spacer tools to quickly provide straight alignment of and proper grout spacing betveen tiles. In addition, the invention helps to provide a more consistent, level finished surface. | 4 |
STATEMENT OF THE INVENTION
This invention relates to electromechanical linear actuators and more particularly to such actuators having a manual override capability and accurate position indication of the actuated device during automatic and manual operating modes of the actuator.
BACKGROUND AND SUMMARY OF THE INVENTION
Electromechanical linear actuators are well known and have many and diverse uses. For example, in the treatment of potable waters, linear motion valve actuators often serve to regulate the feedrate of a gas feeder, typically chlorine, to the potable waters for disinfection thereof.
In the regulation or control of a linear motion valve feeding chlorine gas to potable waters, for example, a conventional analyzer, disposed externally to the present actuator, generates signals indicative of the quantity of residual chlorine in the water. A controller, maintained at a desired set-point of residual chlorine, receives the analyzer signals and compares the analyzed residual chlorine in the treated water with a desired residual chlorine preset into the controller. The controller generates A.C. signals in response to the comparison; these signals are fed to a reversible A.C. motor associated with the present actuator mechanism. The motor positions an output rack which functions to control the chlorine feed valve. Thus, if a higher residual is desired, the controller will cause the motor to run in a forward direction to open, or further open the linear motion valve, and conversely when the residual is to be reduced.
It is desirable in such applications that an accurate indication of valve position be made known to the controller and operator. Further, the manual override means of any automatically controlled electromechanical linear actuator should be readily accessible to the operator as well as simple to operate.
The present actuator device maintains a valve position indicator, and an output rack indicative of the output of the valve, directly coupled in both automatic and manual operation modes. Mode change, i.e., automatic to manual, or vice versa, may easily be made by the simple expediency of moving a knob. The linear actuating device may be mounted in a gas feeder cabinet, for example, where the knob is readily accessible from a front panel thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the assembled electromechanical linear actuator of the present invention.
FIG. 2 is a broken-away perspective view of a portion of the actuator of FIG. 1, the main rotating shaft shown severed, and components associated with the severed shaft enlarged for purposes of clarity of illustration.
FIG. 3 is a broken-away partially sectioned and partially diagrammatic view of the actuator of FIG. 2 taken along line 3--3 thereof, portions in phantom, the main rotating shaft and components associated therewith shown partially sectioned and part in phantom.
FIG. 4 is a fragmentary view of FIG. 3 illustrating the actuator in a manual override mode.
FIG. 5 is a elevational view of the actuator of FIG. 3, the actuator housing shown in section and portions of the actuator removed for clarity of illustration.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 of the drawings illustrates the present actuator 10 provided with a housing of mating halves 12--12', suitably plastic, and means 14 for joining them prior to mounting to a gas feeder cabinet (not shown), for example. A knob 16, readily accessible to an operator, is pulled to manually override automatic operation of the actuator. Rotation of knob 16 causes main rotating shaft 18 to rotate therewith, causing an output rack member 20 (FIG. 3) to travel for control of the linear motion valve 21 (in phantom) which regulates the feedrate of chlorine gas (indicated by arrow 23) to the water. Rack 20 is protected from dirt and contaminants by a pair of bellows 22--22 secured to gear housing unit 24 by clamps 26--26 at their inner ends, and to the outer ends of rack 20 by clamps 26'--26'. Thus, movement of the rack (and bellows) in either direction controls the gas feeder linear motion valve 21 (inspection) by suitable or conventional means. A gasket 27 is provided between the housings 12--12'.
Referring now to FIGS. 2 and 3, alternating current from a suitable source (not shown) supplies power to a reversible permanent split capacitor motor 28 through terminal strip 30. Motor 28 is typically 115 volts, 60 cycle, 1.14 rpm, with continuous duty 40 inch-pounds starting torque. Motor 28 is screw mounted within motor mount 32 integrally formed to gear box 34 secured to gear housing unit 24 through housing 12 by a plurality of threaded spacers 36.
Drive shaft 40 of motor 28 is provided with gear 42 which coacts with pinion 44 secured to main rotating shaft 18. Rotation of pinion 44 causes output rack 20 to travel depending upon the direction of rotation of drive shaft 40. Pinion 44 is suitably made of plastic to obviate any need for lubrication between it and gear 42 and rack 20.
Main rotating shaft 18 is provided with an inner transverse recess 48 and an outer transverse recess 50, both of which are capable of engaging projection 52 secured to gear housing unit 24. Thus, in the embodiment illustrated in FIG. 3, projection 52 is engaged within outer recess 50 permitting automatic operation of the present linear actuator 10. When knob 16 is pulled, as illustrated in FIG. 4 of the drawings, projection 52 engages inner recess 48 of main rotating shaft 18, causing pinion 44 to be disengaged from gear 42. The engagement of the pinon 44 with the rack 20 is maintained allowing rotation of knob 16 to rotate pinion 44, secured to main rotating shaft 18 to cause rack 20 to move for manual control of the gas feeder linear motion valve. Rack 20 is provided with internal threads 54 at each end thereof (FIG. 5) to facilitate connection to the linear motion valve.
Manual override may be desirable in several instances, i.e., where an operator desires to increase or decrease the residual chlorine in the treated water above or below the predetermined set-point respectively, where the volume of water being treated is suddenly changed, where electrical power fails, and the like.
The position indicating means for both manual and automatic operation of the present actuator is clearly shown in the drawings, and more particularly to FIG. 2 thereof. In either mode of operation, main rotating shaft 18 is rotatable in either direction. Shaft 18 is secured within sleeve 60 by means of pin 62 pressed into a hole provided in shaft 18 while engaging a longitudinal slot 64 formed through sleeve 60. Thus, rotation of shaft 18 rotates sleeve 60 accordingly. Retainer ring 66, disposed around an inner portion of sleeve 60, functions to pinch sleeve 60 onto shaft 18. A plastic spacer member 68 is positioned outwardly of pin 62 and is caused to fit loosely or float around sleeve 60. When knob 16 is pushed towards housing 12 such that outer recess 50 is engaged by projection 52, as depicted in FIG. 3 of the drawings, pin 62 slides along slot 64 to urge the outer surfaces of spacer 68 to contact spring lever 70 (FIG. 5) of normally open switch 72 to thereby close a position feedback circuit, later described, and allows motor 28 of the actuator to operate in the automatic mode. Switch 72 is mounted on the multiangled bracket member 74 which is threadedly attached to spacers 36. When it is desired to manually override the automatic mode of operation, knob 16 will merely be pulled (FIG. 4) to cause pin 62 to retract along slot 64 to abut well 106 while projection 52 engages inner recess 48, allowing lever 70 of switch 72 to return to its relaxed position while pushing floating spacer member 68 inwardly along sleeve 60 and disposing switch 72 back to its normally open position, thus opening the circuit and removing the supply of power to the motor 28.
At the outermost end of sleeve 60 is positioned a feedback or position indicating potentiometer 76 screw mounted to a plate 78 by screws 80. Plate 78 is provided with a slot 82 which receives rod 84 extending outwardly from bracket 74. Plate 78 and rod 84 prevent potentiometer case 77 from rotating, i.e., even though shaft 18 and sleeve 60 are rotating, potentiometer case 77 will not rotate therewith. Potentiometer shaft 86 (FIG. 3) is secured within a central passageway 88 formed at the outer end of sleeve 60 by means of a set screw 90.
Attached to potentiometer shaft 86 is a conventional internal wiper which rotaes with the rotation of main rotating shaft 18 and sleeve 60, enabling potentiometer 76 to provide a linear voltage responsive to the position of output rack 20, if a constant current is applied across the potentiometer, due to the synchronous movement of the wiper and rack. Thus, any change in the resistance of the potentiometer is precisely correlated to any change in position of the output rack.
Gear backlash between rack 20 and pinion 44 is made to equal the clearance distance between pin 62 and slot 64 in sleeve 60 to thereby eliminate possible potentiometer position indicating errors when the direction of rotation of the main rotating shaft and sleeve is reversed.
Cams 94 and 96 are secured to sleeve 60 inwardly potentiometer mounting plate 78, rotate with the sleeve, and function to contact normally closed limit switches 98 and 100 respectively, mounted to bracket 74 (FIG. 5), to limit linear travel of output rack 20 in either direction of opening motor 28 operating circuit located within housing 12--12'. The motor operating circuit includes the two energizing leads of the a.c. reversible motor 28, each in series with a limit switch 98 or 100. The position feedback circuit, also located within housing 12--12', includes the feeback potentiometer 76 and switch 72.
A bearing member 104 for main rotating shaft 18 is disposed in the inner wall of housing 12 (FIG. 3). Well 106 is integrally formed with housing 12 and extends outwardly concentrically about bearing 104, providing mechanical support thereto while continuously housing therein a flange 108 (FIG. 2) formed at the innermost end of sleeve 60 whether the actuator is operating in automatic or manual mode. As mentioned above, well 106 is abutted by pin 62 when automatic operation of the actuator is manually overridden.
The use of a position indicating potentiometer for indicating positions of linear apparatus is known. The potentiometer may be connected directly to a suitable controller, described hereinabove, for position feedback and for visually indicating, typically, by dial, bar graph, or digital means, the exact position of the linear motion valve to be controlled.
Since output rack 20 moves in synchrony with the potentiometer wiper, in both manual and automatic modes, it is apparent that the precise positioning of the linear motion valve, regardless of direction of rotation of the shaft and sleeve, may readily be visually displayed.
Modification and changes may be made to the present device by one skilled in the art without departing from the spirit of the invention. For example, a bearing 110 (FIG. 3) adjacent an interior end portion of gear housing unit 24 may be contacted by a snap ring 112 disposed at an outer end of rack 20 to automatically stall motor 28 to provide an additional safety measure to the present actuator. A remote manual electrical switch could replace a controller. Switch 72 of the position feedback circuit would then be wired in series with common lead of motor 28. Additionally, another potentiometer may be suitably positioned on the present actuator for indicating position of the same linear device to another instrument, and so forth.
The present actuator may be adapted for use advantageously in other applications, such, for example, as controlling the stroke length of a diaphragm metering pump, the height of a table, platform, etc. to be raised, and the like. | Electrochemical linear actuator for automatically controlling a gas feeder linear motion valve, for example, is provided with a readily accessible and simple to operate manual override capability, while yet affording accurate position indication of the linear motion valve being controlled in both automatic and manual modes of operation. | 8 |
BACKGROUND OF THE INVENTION
The present invention relates to a device for a missile (or the like) which comprises a sustainer motor located at a distance from a rear surface of the missile, a motor nozzle arranged centrally in the rear surface, and a blow pipe which extends between the sustainer motor and the motor nozzle.
For defense purposes, enemy targets are often attached with the aid of guided projectiles or missiles. For example, such missiles may have a range of less than 5 km, and are generally quite small in size, with a diameter of between 100 and 150 mm. Known missile assemblies of this type usually include the following missile structure: wings, warhead, sustainer motor, gyroscope, battery, electronics, control members in the form of nozzle control members, and signal receiver or wire spool and tracer. When using nozzle control members, it is desirable to position the nozzle of the sustainer motor in a central portion of the rear surface of the missile. For the missile to maintain a stable movement during its trajectory, while also remaining easy to control, the aerodynamic centre of pressure must be behind and relatively near the centre of gravity of the missile. This requires the stabilization wings to be located in the vicinity of the centre of gravity of the missile. For the centre of gravity of the missile to remain fixed even after a powder charge of the propellant motor burns up, the powder charge of the propellant motor should also be located in the missile in such a way that the centre of gravity of the powder motor is near or coincides with the resulting centre of gravity of the missile. These two requirements, both of which must be fulfilled simultaneously, require the stabilization wings of the missile and the powder charge of the propellant motor to be located in the same portion of the missile, which is usually the middle portion. Certain apparatus, such as a warhead may be placed forwardly of the propellant motor, while other apparatus should be positioned between the propellant motor and the rear surface for proper functioning. Among such rearwardly positioned apparatus or components are the signal receiver or wire spool, and the nozzle control members and the tracers.
Assuming the wings of the missile, the propellant motor, warhead, nozzle control members, tracer and signal receiver are located in such a way that the resulting centre of gravity will be in the middle of the propellant charge, the conclusion arises that the remaining apparatus, including the gyro, electronics and battery must be located somewhere between the rear end of the propellant motor and the rear surface of the missile. However, in this space, a blow pipe extends from the rear end of the sustainer motor to the rocket motor nozzle, and if this pipe were to be arranged centrally through a longitudinal axis of the missile, the space available for the gyro, electronics and battery will be a ring-formed space between the centrally positioned tube and the inner surface of the missile body. If the outer dimension of the blow pipe, including its insulation, is assumed to have a diameter of 25 mm, the space for the gyro, electronics and battery will have a minimum dimension of 30-35 mm. While it is possible to design the electronics assembly and the battery so that there will be sufficient room for them in such a space, it is considerably more difficult to make room for a gyroscope in the remaining space, which is limited from a radial point of view. The miniature gyroscopes available in the market usually have a minimum diameter of between 50 and 60 mm. It is possible, of course, to design gyroscopes which can be installed in the ring-formed space available, but the costs of such a gyroscope will be many times greater than the costs of conventional miniature gyroscopes. In order to solve this problem, it has hitherto been proposed to over-dimension the missile from the point of view of the diameter, which, however, also involves increased costs.
SUMMARY OF THE INVENTION
A purpose of the present invention is to create a device which solves the problems involved in making room for a conventional gyroscope or like assembly in a missile of optimally small diameter. A novel feature of the new device is that the blow pipe includes a first section extending from the motor which is essentially parallel to and is eccentrically positioned a substantial distance from the longitudinal axis of the missile. An attached rear portion of the blow pipe includes a second section with two bends which provide for connection to the motor nozzle which is located centrally in the rear surface of the missile.
BRIEF DESCRIPTION OF THE DRAWINGS
An embodiment of the present invention will be described in the following, with reference to the accompanying drawings, in which
FIG. 1 shows a longitudinal section of a missile utilizing a preferred embodiment of the invention, and
FIG. 2 shows a longitudinal enlarged section of the embodiment according to FIG. 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
In FIG. 1, the body structure of the missile is designated by the numeral 1, and the wings of the missile, only two of which are shown in the figure, are designated 2. In the middle portion of the missile a propellant motor or sustainer motor 3 of the powder rocket motor type is arranged. A warhead 4 is positioned in front of the propellant motor. The missile also includes one or more nozzle spoilers 5, arranged at the rear surface of the missile, which influence the propellant gas jet emitted centrally from the rear surface of the missile in response to controls from the nozzle control member which is symbolized at 6 and is placed in a unit which forms the rear end wall of the missile. In the centre of the end wall, a nozzle 7 is placed for connection with the propellant motor 3. Between the rear section 8 of the propellant motor 3 and the motor nozzle 7 is a blow pipe which includes a first section 9 and a second section 10 attached in a way described in more detail in the following. The first section 9 is eccentrically positioned in the space between the rear parts of the motor 3 and the rear parts of the missile. The space also includes a gyroscope 11 of a conventional type requiring radial space, as well as a battery 12 and electronic equipment 13. On the outside of a partition of the missile and behind the wings 2 there is also a wire spool 14. A tracer is designated 15.
Apart from the special arrangement of the blow pipe 9, 10, the remaining components are each of conventional construction, and the arrangement of the components requires the centre of gravity of the missile to be located at a point indicated Tp, while its centre of pressure is located rearwardly of centre of gravity, at Tc.
As shown in FIG. 2, a recess 16 in the rear end 8 of the propellant motor is arranged for connection with the blow pipe 9, which extends eccentrically in relation to the longitudinal axis 17 of the missile. From said recess 16, said first section 9 extends in the form of a straight, first pipe part rearwardly and parallel to the axis 17 of the missile. The longitudinal axis 18 of the first pipe part is moreover arranged at a radial distance r which in the embodiment shown is approximately one half of the radius R of the internal space in the missile at the part of the missile in question. The relation between the distances r and R constitute an ideal case, but it may be varied in dependence on, among other things, the total outer diameter of the blow pipe. In all, the distance r should be 0.2-0.8 of the distance R. In principle, however, the first pipe part 9 can be arranged close to the inside of the hull of the missile.
The first pipe part 9a extending has insulation 9b internally therein. At its front or forward end, the first pipe part 9a is sealed against the outlet flange 8a via a seal 19, which prevents leakage of propellant gas. The insulation 9b of the tube is positioned for connection with insulation 8b applied on the inner wall of the rear section 8.
The second section 10 of the blow pipe comprises a straight second pipe part 10a which extends substantially at right angles to the longitudinal axis 18 of the first pipe part. Also the second part 10a has insulation extending internally thereto, which in the present embodiment is designated 10b. The second pipe part 10a is made with a first tubular recess 10c, into which the straight first pipe part 9a extends and is supported with its rear end, and a second tubular recess 10d, in which the motor nozzle 7 is supported.
At the first recess 10c, the insulation of the second pipe part 10b is provided with a first recess 10e, which permits gas to flow into the second pipe part 10a and to the motor nozzle 7. At the second recess 10d the insulation of the second pipe part 10b is provided with a second recess 10f for the motor nozzle 7. The second pipe part 10a is provided with a cover 10g which is sealed against the inner wall of the pipe 10a via a sealing ring 20. The second pipe part 10a is fastened to the wall formed by the unit 6. The cover 10g provides for partial insulation of the second tube and the parts of the motor nozzle 7. The first pipe part 9a is sealed in the corresponding way against the recess 10c of the second pipe part via a sealing ring 21. The motor nozzle 7 has an outer part 7a made of metal and an inner part 7b made of graphite. The insulation of the second pipe part 10b is adapted to said inner part 7b.
In the present embodiment, connection of the first pipe part 9a to the motor nozzle 7 is obtained via two 90° bends, the configuration of which, however, can be varied. The material in the blow pipe sections and the insulation for these and the arrangement shown of the embodiment of the blow pipe parts allows the flow and heat problems arising in the blow pipe to be solved. It should then be noted that the temperature of the gas conducted in the blow pipe has values of approx. 2000° C., and that the gas velocity can be in the magnitude of 20% of sonic speed and higher. The material of the pipe parts 9a and 10a may consist of special steel or light metal alloys which are known in themselves, and the same applies to the insulations which may comprise asbestos filling and the like.
The inner diameter of the missile surround in the space in question may vary between 100 and 150 mm, and the first pipe part with insulation may have an external diameter of approx. 25 mm.
The blow pipe arrangement shown is also intended to provide for efficient manufacturing processes for the missile itself. The material in the rear end of the motor and its insulation also may comprise of conventional materials.
The invention is not limited to the embodiment shown above as an example, but can be subject to modifications within the scope of the following claims. | In a missile assembly (or the like) including a motor nozzle positioned in a central portion of a rear surface of the missile and a sustainer motor positioned a distance away from the rear surface of the missile, the invention comprising a blow pipe joining the sustainer motor and nozzle assembly, with the blow pipe including a portion extending along an axis which is eccentrically positioned with respect to the longitudinal axis of the missile. | 5 |
This invention was made with United States Government support under Government Contract/Purchase Order No. DE-FC26-02NT41246 awarded by DOE. The government has certain rights in this invention.
TECHNICAL FIELD
The present invention relates to hydrocarbon reforming for supplying hydrogen-containing reformate fuels to fuel cells; more particularly, a system for removing sulfur from a reformate fuel stream; and most particularly, to an improved arrangement for continuously desulfurizing a reformate fuel stream.
BACKGROUND OF THE INVENTION
Fuel cells for combining hydrogen and oxygen to produce electricity are well known. A well known class of fuel cells, referred to in the art as “solid-oxide” fuel cells (“SOFC”), includes a solid-oxide electrolyte layer through which oxygen anions migrate from a cathode to combine with hydrogen, forming water at the anode. In an SOFC, electrons flow through an external circuit between the electrodes, doing electrical work in a load in the circuit.
In the prior art, an SOFC is readily fueled by “reformate” gas, which is the effluent from a catalytic hydrocarbon oxidizing reformer, also referred to herein as “fuel gas”. Reformate typically includes amounts of carbon monoxide (CO) as fuel in addition to molecular hydrogen. The reforming operation and the fuel cell operation may be considered as first and second oxidative steps of the hydrocarbon, resulting ultimately in water and carbon dioxide. Both reactions are preferably carried out at relatively high temperatures, for example, in the range of 700° C. to 1000° C. An SOFC can use fuel gas containing CO with the H 2 , the CO being oxidized to CO 2 .
The long term successful operation of an SOFC depends primarily on maintaining structural and chemical stability of the fuel cell components during steady state conditions, as well as transient operating conditions such as cold startups and emergency shut downs. Three types of reformer technologies are typically employed in conjunction with an SOFC (steam reformers, dry reformers, and partial oxidation reformers) to convert hydrocarbon fuel to hydrogen using water, carbon dioxide, and oxygen, respectively, with byproducts including carbon dioxide and carbon monoxide, accordingly.
Known hydrocarbon fuels for use in a reformer are, for example, gasoline, diesel, JP-8, Jet-A, and natural gas. A serious problem in the use of such fuels can be the presence of sulfur and sulfurous compounds. Ultra-low sulfur road fuels, being introduced in Europe and North America, have low levels of sulfur, with limits in the range of 10 to 50 parts per million (ppm) by weight. Some refinery streams and, for example, Fischer Tropsch synthetic diesel fuel are essentially sulfur-free—but when distributed in the fuel infrastructure it is very difficult to consistently deliver fuels with a sulfur level of less than 30 ppm. In some regions of the world, commercial hydrocarbon fuels contain elevated levels of sulfur, e.g., in an amount of about 300 to about 5,000 ppm by weight. It is likely that these high sulfur fuels will continue to be used in some parts of the world and in some industries (for example shipping and aviation) for long into the future. Fuel cell stacks can be particularly sensitive to sulfur—which tends to accumulate in the anode and cut power density and efficiency. Reformer catalysts and washcoat materials may also have some sensitivity to sulfur. In addition, endothermic reformer catalysts operating at low temperature tend to be particularly intolerant to sulfur, which can also adversely affect achievable reformer efficiency. In addition, sulfur can increase the propensity to form soot and other carbonaceous deposits. If coking or sooting occurs, due to a premature gas phase reaction before the fuel enters the reformer, within the reformer or as a post reaction in the system manifolding, the resulting particulate matter can enter the SOFC and degrade its efficiency and performance. Thus the long term successful operation of the fuel cell system is compromised by sulfur in the fuel.
Pending U.S. patent application, Ser. No. 09/781,687, filed Feb. 12, 2001, published Sep. 26, 2002 as US Patent Application Publication No. 2002/0136936 A1, the relevant disclosure of which is incorporated herein by reference, discloses a system and method for trapping impurities and particulate matter, and especially sulfur and sulfur-containing compounds, in energy conversion devices. The system comprises a regenerable trap including a trap element and, optionally, a filter element. The reforming system is fluidly coupled to the trapping system, which is positioned after the reforming system.
A drawback of the disclosed trappng system is that when the trap becomes loaded with trapped material, fuel cell operation must be suspended in order for the trap to be purged of the trapped material and thus regenerated. During such regeneration, the reformer is operated in a fashion to produce a gas suitable for removal of the trapped material (i.e., at high oxygen/carbon ratios) and the reformate gas is passed through the trap, reversing the adsorption process. The effluent from the trap is exhausted from the system via a control valve. A problem with this approach is that the fuel being reformed during regeneration is still contaminated with sulfur. Another problem is that the temperature at the reformer exit may be more than 900 C during start-up which can deteriorate the active materials in the sulfur trap. Yet another problem is that an extra heat exchanger must be used upstream of the reformer to cool recycled anode gas when the recycled gas is used to provide an oxidant for endothermic reforming.
What is needed in the art is a method and apparatus that permits continuous supply of desulfurized reformate to a fuel cell while simultaneously permitting regeneration of the sulfur strap, in an efficient configuration that protects the active materials in the sulfur trap from high temperature modes.
It is a principal object of the present invention to provide a continuous stream of sulfur-free reformate to a fuel cell for continuous operation thereof.
SUMMARY OF THE INVENTION
Briefly described, a system for removing sulfur from a continuous reformate stream comprises first and second regenerable sulfur traps disposed in parallel between a hydrocarbon reformer and a fuel cell assembly. The ends of the sulfur traps are connected to conventional four-way valves such that either trap may be selected for trapping sulfur from the reformate stream, while the other trap is undergoing regeneration by purging out the accumulated sulfur deposits. Thus, the sulfur traps may be loaded and purged alternately, permitting continuous supply of reformate to the fuel cell assembly. In a currently preferred embodiment, selected amounts of hot cathode air exhaust, hot anode gas exhaust and/or steam are used to control the temperature and oxygen concentration in the out-of-service trap, in order to assist in purging and thus regenerating the out-of-service trap. The timing of the adsorption/regeneration modes may be controlled so that regeneration occurs faster than adsorption to assure complete purging of sulfur before the trap is returned to its adsorption mode. In an alternate embodiment, a second reformer is disposed parallel to the first reformer and in series with the second regenerable sulfur trap so that the reformers may also be sequentially regenerated along with the associated sulfur traps. In a preferred embodiment, additional amounts of anode exhaust from the stack may be added to the stream between the regenerating trap and regenerating reformer to further reduce the amount of free oxygen flowing to the reformer to improve reformer regeneration. Alternatively, the amount of cathode exhaust flowing to the regenerating reformer from the regenerating sulfur trap may be reduced or completely switched off to control the temperature of and the oxygen concentration in the regenerating reformer.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will now be described, by way of example, with reference to the accompanying drawings, in which:
FIG. 1 is a schematic drawing of a prior art system for desulfurizing a reformate stream, substantially as disclosed in the incorporated US Patent Application Publication reference, also showing an optional anode recycle loop for thermal reforming;
FIG. 2 is a schematic diagram of a first embodiment of an improved apparatus in accordance with the invention for desulfurizing a reformate stream while providing a continuous stream of desulfurized reformate to a fuel cell assembly;
FIG. 3 is a schematic diagram of a second embodiment of an improved apparatus in accordance with the invention; and
FIG. 4 is a graph showing the switching sequence of valves during the regeneration cycle of the second embodiment.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1 , a prior art system 10 includes a fuel cell stack 12 , preferably a solid oxide fuel cell (SOFC) stack as is known in the art, although an apparatus in accordance with the invention is also useful for use with other types of fuel cell systems, for example, a molten carbonate fuel cell (MCFC) (not shown). A catalytic hydrocarbon reformer 14 receives a hydrocarbon fuel 16 and optionally air 18 and expels a reformate stream 20 . Fuel 16 is preferably selected from the group consisting of, but not limited to, conventional liquid fuels, such as gasoline, diesel, ethanol, methanol, kerosene, and others; conventional gaseous fuels, such as natural gas, propane, butane, and others; and alternative fuels, such as hydrogen, biofuels, dimethyl ether, and others; and synthetic fuels, such as synthetic fuels produced from methane, methanol, coal gasification or natural gas conversion to liquids, combinations comprising at least one of the foregoing methods, and the like; and combinations comprising at least one of the foregoing fuels. A sulfur-adsorptive, regenerable trap 22 containing suitable materials, preferably as disclosed in the incorporated reference or containing a high surface area, nanostructured sorbent of relatively low capacity, adsorptively retains sulfurous compounds passing through trap 22 , for example, hydrogen sulfide (H 2 S) and sulfur dioxide (SO 2 ) as may be present in stream 20 .
In a currently preferred embodiment, trap 22 includes a filter element and a trap element. The filter element includes a particulate filter in the first chamber of the trapping system wherein the particulate filter includes a washcoat disposed on the filter material.
Various sensors such as, for example, temperature sensor 21 and/or pressure differential sensor 23 can be positioned in electrical communication with trap 22 to detect the sulfur level content of trap 22 , and to control and schedule the trap's regeneration based on those levels. Trap 22 can then be regenerated by adjusting the air-fuel ratio of the reformate, or by increasing the operating temperature of the trap, as known in the art.
When in the fuel cell operation mode, Desulfurized stream 24 is passed into the anode side 26 of fuel cell stack 12 where it reacts with oxygen provided from air 27 on the cathode side 28 to produce electricity as is well known in the art. Optionally, after being cooled by heat exchanger 35 , a portion 30 of anode exhaust 32 may be recirculated into reformer 14 , assisted via a high-temperature, pressurized pump 34 , to provide the oxidant for endothermic reforming; the balance 36 of anode exhaust 32 is disposed of in known fashion. Hot cathode exhaust air 38 is passed to atmosphere. Waste heat 40 from fuel cell stack 12 may be directed into reformer 14 , for example, by proximity thereto, to assist in endothermic reforming.
Desulfurizing trap 22 requires periodic regeneration as described in the incorporated reference. A three-way valve 42 downstream of trap 22 , after receiving a control signal from various monitoring sensors such as sensors 21 , 23 , permits the venting of desorbed sulfurous materials to a suitable destination 44 when regeneration is required and SOFC 12 may be taken offline.
Referring to FIG. 2 , a first embodiment 110 in accordance with the invention, like prior art embodiment 10 , comprises a fuel cell stack 12 , having anode side 26 and cathode side 28 , and a reformer 14 for receiving fuel 16 and air 18 , and a portion of recycled anode gas 30 , as may be needed for generating a reformate stream 20 . The improvement in first embodiment 110 is the provision of first and second equivalent regenerable traps 122 a , 122 b arranged in parallel flow. Each of traps 122 a , 122 b may be constructed of a trap element, and optionally a filter element, as disclosed in the incorporated reference. A first four-way valve 160 and a second four-way valve 162 are connected across the respective entrances and exits of traps 122 a , 122 b as shown in FIG. 2 such that reformate stream 20 may be directed as desired alternately through either trap 122 a or trap 122 b as desulfurized stream 24 .
The arrangement shown in FIG. 2 permits reformate stream 20 and desulfurized stream 24 to be directed into fuel cell stack 12 continuously by the selection of either trap 122 a or trap 122 b . Likewise, this arrangement permits the offline regeneration of the traps preferably in a direction counter to the flow of reformate, of whichever trap is not in service. As shown in a first operating mode in FIG. 2 , trap 122 a is selected for online reformate flow and trap 122 b is offline. To change to a second and alternate operating mode, actuation of valves 160 , 162 serves to bring trap 122 b online and places trap 122 a offline.
In the first operating mode, as shown in FIG. 2 , all or a portion 146 of hot, oxygen-depleted cathode exhaust 38 may be sent to offline trap 122 b via a backflush inlet 166 of valve 162 to permit reverse-flow regeneration of the offline trap to appropriate waste destination 44 . Other gases 148 may be supplied to valve 162 as desired, either with or instead of cathode exhaust portion 146 , for example a mixture or all or part of the cathode exhaust 38 and part of the anode exhaust 36 and optionally including steam 150 as a means to control temperature and oxygen concentration of gas 152 for trap regeneration.
In operation, the valves are switched periodically so that the just-regenerated trap now receives reformate and the saturated trap may be regenerated. The regeneration period of the storage and regeneration can be relatively short, for example, less than one minute for conditions wherein the temperatures of storage and regeneration are approximately equal, and several minutes if the temperatures are substantially different. The system is balanced so that offline regeneration occurs somewhat faster than online adsorption. In this way, the traps are completely purged of sulfur prior to being placed back online with the stack. This timing is easily achieved with choice of appropriate adsorbent materials, regenerating gases, and temperatures, as known in the art. Preferably, the proportions of gases 146 , 148 , during the regeneration, are adjusted so that when the trap is placed back online to the fuel cell stack, no oxygen is present in the stream. For example the flow of cathode exhaust 146 to valve 162 , containing amounts of oxygen, can be switched off and steam or anode exhaust contained in the regeneration gas 152 can remain flowing at the end of the regeneration cycle—such that no free oxygen reaches the fuel cell stack 12 in the fuel gas and, optionally, so that the surface of active materials in the traps 122 a/b can be reduced.
The state of the traps 122 a , 122 b can be continuously monitored by differential pressure, temperature, and inlet and exhaust gas composition sensors, such as sensors shown in FIG. 1 as 21 , 23 , together with predetermined control algorithms.
Referring now to FIG. 3 , a second embodiment 210 in accordance with the invention includes first and second traps 222 a , 222 b , first and second four-way valves 260 , 262 , and a fuel cell stack 12 . The novel feature of embodiment 210 is that two alternate reformers 214 a , 214 b are also provided in parallel and are included in the changeable pathway between the four-way valves 260 , 262 . Thus, not only the traps but also the reformer catalysts and catalyst substrates may be backflushed of contaminants during regeneration mode.
In the first operating mode as shown in FIG. 3 , all or a portion 246 of hot, oxygen-depleted gas from cathode exhaust 38 may be sent to the offline trap and reformer via a backflush inlet 266 of valve 262 to permit reverse-flow regeneration of the offline trap and reformer to appropriate waste destination 44 . Other gases 248 may be supplied to valve 262 as desired, either with or instead of cathode exhaust portion 246 , for example a mixture of all or part of the cathode exhaust 38 and part of the anode exhaust 36 and optionally including steam 250 as a means to control the oxygen concentration of gas 252 for trap and reformer regeneration. This can be useful for systems using fully endothermic reforming at relatively low temperatures, because substantial storage of sulfur on the catalyst is a known source of deterioration that is desirably mitigated. Preferably, the amount of free oxygen flowing from the regenerating trap and into the regenerating reformer may be reduced by introducing additional amounts 36 a of anode exhaust 36 via three-way valve 270 .
To prevent residual oxygen from migrating to the anode, from the regenerating cycle, near the end of the regeneration cycle, and before valves 260 , 262 switch to reverse the regeneration/adsorption modes, the flow of cathode exhaust portion 246 to valve 262 can be switched off and steam and/or anode exhaust can remain flowing to the leg being regenerated. Alternately, to consume any residual oxygen, the amount of anode exhaust 36 a being introduced to the reformer via valve 270 may be adjusted to achieve a stoichiometric or richer fuel/air ratio entering regenerating reformer 214 b near the end of the regenerating cycle. The timing of either introducing additional amounts of gas 36 a or switching off the flow of exhaust portion 246 is best shown in FIG. 4 . In FIG. 4 , line 280 represents the period of time of the full cycle (t) over which either leg completes its reforming and regeneration cycle. During time interval 282 , reformer 214 a is in its regeneration period or cycle; during time interval 284 , reformer 214 b is in its regeneration period or cycle. As shown, near the end 286 of their respective cycles, purge phase 288 begins during which additional amounts of gas 36 a are introduced into the respective reformer or the flow of cathode exhaust portion 246 is switched off. Preferably, the purge phase continues beyond the end of the regeneration cycle to minimize the amount of oxygen present in the reformer when reforming again begins.
The order and strategic placement of components in the first and second embodiments ( FIGS. 2 and 3 ) to match or nearly match their optimal temperature of operation allows the components to operate at appropriate temperatures without the need for heat exchanger 35 and the use of a lower temperature recycle pump 134 , as used in prior art system 10 , thus offering a substantial reduction in weight, cost and complexity. For example, by placing reformer 14 downstream of and in thermal proximity of the stack and stack exhaust outlets, as shown, optimal, incrementally decreasing operating temperatures for the inlet and outlet of the stack of 650° C. and 850° C.; for the inlet and outlet of the reformer of 800° C. and 700° C.; for the inlet and outlet of the regenerable traps of 650° C. and 600° C.; and for the inlet to the pump, of 550° C. can be achieved.
Embodiment 110 is especially useful with low-sulfur fuels such as natural gas and low-sulfur gasoline. Embodiment 210 is especially useful with heavier fuels and high-sulfur fuels such as diesel fuels, JP8, or current jet fuel. This is because it is practical to make a robust endothermic reformer with light, low-sulfur fuels, but heavier and high-sulfur fuels tend to create problems with coking and contamination of the reforming catalysts; thus a periodic and frequent regeneration of the reformer catalyst is attractive.
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 system for removing sulfur from a continuous reformate stream feeding a fuel cell stack. First and second sulfur traps are disposed in parallel between a hydrocarbon reformer and the fuel cell stack. The ends of the sulfur traps are connected to conventional four-way valves such that either trap may be selected for trapping sulfur from the reformate stream, while the other trap is undergoing regeneration by backflushing the accumulated adsorbed sulfur deposits. Thus, the sulfur traps may be used and stripped alternately, permitting continuous supply of desulfurized reformate to the fuel cell assembly. In a currently preferred embodiment, the hot cathode air exhaust is used to assist in stripping the out-of-service trap. In an alternative embodiment, two reformers are provided and the reformers are alternately regenerated along with their respective traps. | 2 |
BACKGROUND OF THE INVENTION
(1) Field of the Invention
The invention relates to a boring appliance for producing a concrete element in the ground with a vehicle.
A boring appliance of this type is known from JP 56 031 928 A, in which in addition to the boring tool a complete preparation and mixing installation for concrete are placed on a carriage.
(2) Description of Related Art
In the case of loose soil, in ground water or for concrete piles, which are to be produced in displaceable soils, preferably the following production procedures are used:
boring methods using continuous, long soil augers, displacement boring methods, in which essentially long tubes are turned or rammed into the ground, the cropping out ground being displaced to the side, methods in which long soil augers are surrounded with a rotary encasing tube and both the auger and the tube are simultaneously introduced into the ground.
Such methods are essentially based on the same concreting procedure. After the augers or enveloped augers or displacement tubes have been brought to the final depth, the tube and/or auger is retracted and during retraction concrete is pumped into the resulting space or cavity through inside or soil-sided openings in the auger or tube. The introduction of concrete preferably takes place under a low pressure to ensure that no soil from the borehole wall can pass into the cavity.
The use of pumpcrete has a positive effect on the production rate of such piles.
According to the prior art, such as is e.g. known from U.S. Pat. No. 3,255,592, the concreting of such piles takes place in that at the outside or air-sided end of the boring tool, i.e. either at the outside end of the continuous auger or at the outside end of the displacement tubes, a concreting hose is fixed and leads to a concrete pump which is supplied by mobile or travelling mixers. As the concreting head at the end of the concreting auger or tube is constantly moved up and down, it is not recommended that working takes place with a freely hanging hose. During each pump impact the hose is struck and swings through the air. This can easily lead to damage and constitutes a hazard for personnel.
Thus, generally mobile concrete pumps with adjustable distributing masts or towers are chosen. This procedure is practicable in principle, but suffers from the disadvantage that throughout the pile production time it is necessary to have at the building site and expensive concrete pump with adjustable distributing mast, including driver, although the actual concreting process only lasts for a short time.
To economize on the driver, constructions are known such as from U.S. Pat. No. 6,048,137, in which a stationary concrete pump is installed at the building site and from there hoses are laid up to the concreting head on the boring appliance. Since as a result of the rapid operation the boring appliance covers considerable distances, relatively long hoses are used, which in the case of considerable heat suffers from the disadvantage that in such long hoses frequently blockages occur due to overheating. A further risk is that such hoses can be damaged during the movement of the boring appliance. The generally concrete-filled hoses are heavy and are therefore difficult for the site personnel to handle during the movement of the boring appliance. It must constantly be ensured that the hoses are not bent or that the tracked travelling gear does not pass over the hoses.
As a result of the pressure surges of the plunger or piston pumps the hose on the ground scrapes on the substrate, which leads to damage to the hose casing or jacket.
U.S. Pat. No. 5,967,700 discloses a boring appliance with pressure containers on the top of a superstructure from which pulverulent materials or water are injectable directly into the borehole for producing concrete therein.
BRIEF SUMMARY OF THE INVENTION
The object of the invention is to provide a boring appliance, which is usable in a particularly mobile and flexible manner at building sites for producing concrete posts in the ground and which has a simple construction.
According to the invention this object is achieved by a boring appliance for producing a concrete element in the ground with a vehicle on which are located a tower, a concrete pump and a boring tool, which is installed for introduction into the around at tower and by means of the concrete pump and a delivery line concrete can be pumped into a cavity formed by the boring tool for forming the concrete element, characterized in that the concrete pump is detachably held in the vehicle rear region, which faces a front area with the tower.
In one preferred embodiment, the drive of the concrete pump takes place by means of a hydraulic pump unit with its own drive additionally fitted to the vehicle and/or that the drive of the concrete pump takes place by means of the vehicle's own hydraulic pumps.
In another preferred embodiment, on the vehicle, preferably on the side facing the tower, a water tank is provided.
In another preferred embodiment, the concrete pump is detachably connected to the vehicle by means of a holding device.
In another preferred embodiment, from a transfer point firmly fixed to the tower, a movable hose line can passes to the concreting head at the outside end of the boring tool.
In another preferred embodiment, the concrete pump is a single or multiple plunger pump, a hose pump, a screw pump or an eccentric screw pump.
In another preferred embodiment, the concrete pump is hydraulically driven.
In another preferred embodiment, the boring tool is a simple soil auger, a soil auger with rotary encasing tubes or a displacement boring tool.
In another preferred embodiment, the concrete pump has a feed hopper.
In another preferred embodiment, the vehicle has a superstructure rotatable with respect to a chain or track unit and that the concrete pump is suspended on the superstructure.
In another preferred embodiment, to facilitate concrete filling, the concrete pump is located in an area close to the ground and offset with respect to the superstructure.
The special nature of the appliance according to the invention is that in the vicinity of the counterweight of a vehicle is fixed a concrete pump from which a fixed line leads to the boring appliance tower. The fixing of the concrete pump to the boring appliance avoids problems with the hose line and makes unnecessary the use of a concrete pump with an adjustable distributing tower.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an elevational view of a boring appliance in accordance with the present invention.
FIG. 2 is a plan view of a first embodiment of the boring appliance of FIG. 1 .
FIG. 3 is a plan view of a second embodiment of the boring appliance of FIG. 1 .
DETAILED DESCRIPTION OF THE INVENTION
The invention is explained in greater detail relative to FIGS. 1 to 3 .
FIG. 1 shows an embodiment with a boring appliance in which the bored piles are produced according to the boring method using a continuous soil auger. After introducing the auger to the final depth of the pile to be produced, on retracting the auger concrete is introduced into the resulting cavity in the ground. For this purpose the concrete pump 1 with feed or filling hopper 16 , which is fixed to the rear or tail of the superstructure 9 in the vicinity of the counterweight 20 of a vehicle 22 , is supplied with concrete from a mobile mixer. The concrete is delivered by means of a concrete delivery line 2 to a fixed transfer point 8 on the tower 4 of the boring appliance. From said fixed transfer point 8 , further transport takes place by means of a movable hose line 13 to concreting head 14 , which is fixed to the outside end of the auger. This movable hose line 13 makes it possible for the drive to be moved up and down with the concreting head 14 .
In the embodiment shown the concrete pump 1 has a separate drive unit 5 in the form of a hydraulic pump unit.
The concrete pump 1 is fixed with a mounting support 6 in detachable manner to the rear of the superstructure 9 .
By means of a turntable 10 the superstructure 9 is connected to the chain or track unit 11 . The concrete pump 1 is fixed so far away from the chains or tracks that the boring appliance can be rotated entirely around the chain or track unit 11 without the concrete pump 1 scraping thereon.
In addition to the concrete pump 1 a water storage tank 7 is located at the rear of the superstructure 9 .
FIG. 2 is a systematic plan view of an inventive embodiment in which the feeding of the filling hopper 16 of concrete pump 1 takes place from the rear.
FIG. 3 is a systematic plan view of an inventive embodiment, where the feeding of the filling hopper 16 of concrete pump 1 takes place from the side.
The arrangement of the concrete pump 1 in the rear area 12 of the superstructure 9 has the following advantages. With respect to the heavy tower 1 with boring drive and boring tool, it constitutes an additional counterweight and consequently improves the stability of the boring appliance. This is particularly useful if the continuous soil auger is difficult to pull during concreting and consequently high tensile forces are activated. A further advantage is that from the outlet port 3 of the concrete pump 1 a substantially fixed laid concrete delivery line 2 is led up to a transfer point 8 fixed to the tower. This has the advantage that during the movement of the boring appliance or in the case of a boring process there is no risk for the concreting line between the concrete pump and the concreting head 14 . The concrete delivery line 2 is short, cannot bend and is not damaged by the tracked travelling gear on moving to the next boring starting point. The concrete delivery line 2 carries out essentially the same movements as the superstructure 9 on turning or moving.
Further advantages of this substantially fixed laid line 2 is that the concrete delivery line can be protected against increased solar radiation and therefore heating by the fitting of sun protection plates or separate cooling devices 17 . A premature hardening of the concrete in the line can consequently be prevented.
Another advantage of the appliance combination according to the invention is that there is no need for separate operating personnel for the concrete pump 1 . Due to the fact that the concrete pump 1 is in the immediate vicinity of the excavator driver, it is possible for the latter to monitor the filling process during concreting. The excavator driver can directly contact the concrete delivery vehicle driver.
A further advantage is the shortness of the concrete delivery lines between the concrete pump and transfer point 8 . As a result of the lower jacket friction losses in the pipe cross-section more and faster pumping is possible.
The substantially linearly laid concrete delivery lines 2 along the superstructure 9 and tower 4 lead to reduced resistance during concrete pumping and reduce the blockage susceptibility. In addition, the substantially linear connections can largely be in steel pipe form, which reduces friction during concrete delivery as compared with rubber hoses.
Numerous constructional variants are possible for the concrete pump 1 . Preferably, for pumping the concrete, use is made of plunger pumps with relatively long plunger strokes. The plungers are driven by means of hydraulic cylinders. The necessary oil quantity per time unit and the pressure are produced by means of hydraulic pump units.
Another variant is constituted by hose pumps, where the concrete delivery essentially takes place in that the concrete is moved forwards by squeezing elastic hoses within the hose line. If excessive feed pressures are not required, it is also possible to use screw pumps or eccentric screw pumps.
The driving of the concrete pumps 1 generally takes place through an additional hydraulic pump unit 5 , which provides the necessary oil quantities and oil pressures. However, since during the concreting process the full capacity of the oil hydraulics of the vehicle or excavator is not used, it can be appropriate not to have an additional hydraulic pump unit 5 and instead use the vehicle hydraulics. This economizes on fuel and the technical costs are reduced.
The fixing of the concrete pump 1 generally takes place in such a way that the filling hopper 16 of concrete pump 1 can be easily supplied from the concrete mixing vehicles. Due to the fact that the fixing of the concrete pump takes place on the tower-remote side of the superstructure 9 , fixing can occur in such a way that the pump 1 with its feed hopper 16 is only just above the cropping out ground. In this case the distance must be chosen in such a way that on turning the superstructure 9 , the pump structure does not stick on the chain or track unit 11 with its track travelling gear.
To increase the independence of the concrete pump system on the excavator, it is appropriate to provide a water tank 7 on the rear of the superstructure 9 . As on building sites a stationary water supply cannot always be ensured, a water tank is necessary for cleaning the concrete pump 1 during concreting pauses. The water tank 7 located in the rear region 12 also offers the advantage of an additional weight at the rear, which improves the stability of the overall boring appliance system.
The discharge hopper used for supplying the concrete pump 1 can be arranged laterally at the rear of the superstructure 9 in the manner shown in FIG. 1 and then the truck mixers can move up to the boring appliance at right angles to the superstructure longitudinal axis.
In a further variant the filling opening of the concrete pump 1 is positioned in such a way that it is directed towards the extended rear of the superstructure 9 . FIG. 2 is a systematic plan view of an inventive embodiment, in which the filling hopper 16 of the concrete pump 1 is supplied from the rear.
As the emptying of the mobile mixer takes place all the more easily the lower the opening of the filling hopper 16 for the concrete pump 1 , the preferred area for locating the concrete pump 1 is area 15 . Area 15 is fixed in such a way that it does not come into contact with the tracks or chains of the bogie 11 on pivoting the superstructure 9 . In principle, a ground clearance of the pump is only a few decimetres in order to compensate unevennesses of the terrain.
In the sense of the above-described invention concrete is to be generally looked upon as a filling product, which is usable for the production of foundation, sealing and stabilizing elements. | The invention relates to a boring appliance for producing a concrete element in the ground with a vehicle on which are located a tower, a concrete pump and a boring tool, which is installed for introduction in the ground at the tower. By means of a concrete pump and a delivery line concrete is pumped into a cavity formed by the boring tool for forming the concrete element. According to the invention, the concrete pump is detachably held on the rear region of the vehicle, which is opposite a front area with the tower. | 4 |
This application is a continuation of application Ser. No. 573,721, filed Jan. 25, 1984, now abd.
BACKGROUND OF THE INVENTION
The invention concerns link belts, and has particular, though not exclusive, reference to link belts as used as conveyor or support structures in the papermaking and related industries.
Conventional link belts comprise a combination of coils produced from monofilament yarns of circular cross-section joined in interdigitated disposition by hinge wires engaged with the overlapping turns of adjacent coils. In a link belt typical of one type of structure the coils are of oval cross-section and have a major inside dimension of 3.75 mm, the monofilament yarn and the hinge wire being 0.55 mm and 0.9 mm in diameter respectively. In such a structure, ready insertion of the hinge wires, particularly by mechanical means, requires that adjacent coils, at least in practical terms be fully engaged one with another, any diviation from such full engagement reducing the transverse dimension of the hinge wire receiving tunnel formed by the overlapping turns of adjacent coils and material deviation reducing such transverse dimension to an extent sufficient to prevent or to make difficult the insertion of the hinge wire.
It is known in the art that tension introduced into close wound coils by opening up the turns thereof to receive an adjacent coil into interdigitated relationship therewith and which arises from the elastic properties of the material of the coil assists in maintaining engagement of one coil with another, such tension causing successive turns of one coil to grip the interposed turns of the next adjacent coil and, if of sufficient magnitude, to prevent separation of such coils.
The tension in the coil is a function of the elastic properties of the material of the coil, and is accordingly determined by, inter alia, the cross-sectional dimension of the polyester monofilament which forms the coil, and reduction in such dimensions giving rise to a corresponding reduction in the gripping effect of the turns of one coil on those of another.
Having regard to possible non-uniformity of the physical characteristics of adjacent coils, to the incidence of secondary twist therein or to other factors, full engagement of adjacent coils may not occur or may not be maintained, with the result that difficulty may be experienced in effecting hinge wire insertion.
A reduction in the diameter of the monofilament from which the coils are formed, the major inside diameter of the coil remaining unchanged, allows of an increase in the cross-sectional dimensions of the tunnel formed by over-lapping turns of adjacent spiral coils by increasing the extent of permitted engagement of one coil with an existing array of connected coils, and would thus facilitate hinge wire insertion. However, such reduction in diameter would also reduce the spring tension in the coil, and thus the gripping effect of one coil on the interposed turns of the next adjacent coil, and would accordingly increase the likelihood of coil separation, thus making worse the very problem sought to be avoided by the reduction. Furthermore, too ready a opening up of the turns of the coil might well give rise to separation in excess of that required and result in a plurality of turns of the adjacent coil being engaged between two successive turns of a given coil.
An object of the present invention is to provide a tunnel of increased cross-sectional dimensions without prejudice to the capacity of the coils to remain in interdigitated disposition, thus to avoid the difficulties experienced in the mechanical insertion of hinge wires into the interdigitated turns of adjacent helical coils to connect the same together.
SUMMARY OF THE INVENTION
Thus, according to the present invention there is proposed a link belt comprising a multiplicity of helical coils arranged in interdigitated side-by-side disposition, adjacent coils being connected by respective hinge wires, characterised in that the coils are formed from elongate synthetic plastics material initially of non-circular, constant cross-section and having a major cross-sectional dimension extending in the axial direction of the coil.
According to a preferred feature the elongate material is of flat, generally rectangular cross-section.
According to a further preferred feature the elongate material comprises a monofilament yarn.
The invention is thus predicated upon the appreciation that coils formed from elongate synthetic plastics material of non-circular cross-section make possible the attainment of a like level of spring tension in an oval coil of similar major dimension to that of a coil produced from circular cross-section yarns whilst providing a hinge wire receiving tunnel of increased cross-sectional dimensions, the assembly problems experienced in relation to coils made from circular section yarns thereby being avoided.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic cross-section of a single turn of a coil produced from flat monofilament yarns.
FIG. 2 is fragmentary perspective view of a link belt comprising coils produced from flat monofilament yarn.
FIG. 3 is a fragmentary diagrammatic side elevation of the link belt shown in FIG. 2.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawing, the cross-section of the coil material is illustrated in FIG. 1, with the width of the cross-section identified by w and the thickness of the cross-section identified by t. A plurality of coils formed from such a flat monofilament are illustrated in interdigitated relationship in FIG. 2. As therein shown, the coils are of flattened form and have a major internal dimension designated by L. A side view of the belt viewed along the axes of the respective coils is shown in FIG. 3.
We have found that a coil produced from polyester yarn of non-circular cross-section and satisfying the relationship 10<L/a<24 or the relationship ##EQU1## where a is the cross-sectional area of the monofilament yarn and L is the major internal dimension of the coil, has a tension appropriate to the satisfactory mechanical insertion of hinge wires into the interdigitated turns of adjacent coils in the production of papermachine and like clothing.
Whilst it may be that the above ranges for L/a and (a 2 ×10 4 )/L 3 will be proper for all synthetic plastics materials likely to be used in the production of monofilaments suitable for application to the context of link belts, it is to be borne in mind that such ranges may require adjustment in certain instances, possibly by reference to the relationship between the modulus of rigidity of polyester and that of the material in question. Investigation suggests that the ratio of major/minor cross-sectional dimensions of the non-circular monofilament yarn should not exceed 3.0, with a preference for the range 1.3 to 2.5, whilst the thickness of the monofilament yarn should be in the range of 0.2 mm to 1.0 mm and preferably between 0.3 and 0.7 mm.
It also appears to be the case that the greater dimension of the non-circular monofilament in the axial direction of the coil will make more practical the use of oval or flat coils of greater major transverse dimension than is possible with circular cross-section yarns, such a course giving rise to a number of important advantages. Thus, for example, a flat coil of 0.7×0.4 mm monofilament exhibits at least as much springiness as one of like composition of circular cross-section and 0.55 mm in diameter, the springiness being proportional to L/a or to a 2 /L 3 according to the relationship applied. The greater length of the major axis of the flat monofilament, compared with the diameter of the circular cross-section yarn of like cross-sectional area, forces the turns of the coils a like amount further apart when one coil is intermeshed with the adjacent coil with a proportional increase in the spring tension which holds the intermeshed coils together prior to and during the insertion of the hinge wire. The potential increase in spring tension due to the wider material may be utilised by employing a longer (in the sense of major transverse dimension) spiral coil which will allow even greater access space for the hinge wire while having sufficient spring tension to hold the intermeshed coils together.
The increased dimension of the cross-section of the flat monofilament in the axial direction of the coil as compared with the diameter of a circular cross-section monofilament of like cross sectional area and the consequentially greater separation of successive turns of the individual coils on interdigitation does reduce the number of turns per unit of length widthwise of the fabric and makes a significant contribution to a reduction in the weight of the fabric. An increase in major transverse dimension of each flat or oval coil will also give rise to a saving in weight in view of the reduced number of hinge wires and curved portions of coil per unit length of fabric.
It is estimated that a saving in weight of, say, 15% is readily achievable by using flat monofilament and by increasing the major transverse dimension of the coil by, say, 15%, the weight reduction being attributable chiefly to the greater width of the flat monofilament, although the actual weight reduction will vary according to the degree of stretch of the link belt during heat setting under tension.
In addition to the likely saving in cost arising from the reduction in material utilisation, a reduction in the number of coils per unit of fabric length will also be economically advantageous in view of the reduced cost of assembly.
Furthermore, it is the practice, for some applications, to heat set the cloth under tension and then reduce the air permeability by the insertion into the coil channels of filling materials, for example in the form of textured yarns or of tape-like materials, and the time taken, and thus the cost of the filling operation, is reduced by having coils of greater major transverse dimension and hence fewer coils per unit of fabric length.
By way of illustration, the following tables show the values of L/a and a 2 /L 3 for coils produced from polyester monofilaments of different cross-sectional form and dimension, those structures marked with an asterisk not being practical in the sense of being incapable of satisfactory mechanically assisted assembly into a link belt.
TABLE I______________________________________LINK BELT BEFORE HEAT SETTING UNDER TENSION Spiral mmw mmt mmL mm.sup.3L mm.sup.2a mm.sup.4a.sup.2 ##STR1## ##STR2##______________________________________1.1 0.7 5.4 157 0.385 0.148 14.0 9.41.2 0.55 5.4 157 0.238 0.057 22.7 3.6*1.3 0.9 × 0.46 5.4 157 0.38 0.144 14.2 9.22.1 0.55 3.75 52.7 0.238 0.057 15.8 10.82.2 0.4 3.75 52.7 0.125 0.016 30.0 3.0*2.3 0.7 × 0.4 3.75 52.7 0.25 0.063 15.0 11.93.1 0.7 × 0.4 4.5 91.1 0.25 0.063 18.0 6.9______________________________________ Where L = major internal dimension of coil t = minor dimension (thickness) of noncircular coil material w = major dimension (width) of coil material (diameter if circular) a = crosssectional area of coil material
TABLE II______________________________________LINK BELT AFTER HEAT SETTING Spiral mmw mmt mmLf mm.sup.3Lf.sup.3 mm.sup.2a mm.sup.4a.sup.2 ##STR3## ##STR4##______________________________________1.1 0.7 5.8 195 0.385 0.148 15.1 7.61.2 0.55 5.8 195 0.238 0.057 24.4 2.9*1.3 0.9 × 0.46 5.8 195 0.38 0.144 15.3 7.42.1 0.55 4.3 79.5 0.238 0.507 18.1 7.22.2 0.4 4.3 79.5 0.125 0.016 34.4 2.0*2.3 0.7 × 0.4 4.1 68.9 0.25 0.063 16.4 9.13.1 0.7 × 0.4 4.9 118 0.25 0.063 19.6 5.3______________________________________ Where Lf = major internal dimension of the coil t = minor dimension (thickness) of noncircular coil material. w = major dimension (width) of coil material (diameter if circular) a = crosssectional area of coil material.
Link belts constructed from coils of non-circular section material, and particularly from material of approximately rectangular shaped cross-section, also present a greater contact area on their surface than link belts made from circular section materials. The increased contact area can be advantageous in applications requiring a smoother surface or more regular pressure points than presented by normal link belts. For example, the link belts embodying the invention could be used with advantage on the drying section of a paper-making or like machine, a link belt comprising coils made from monofilaments of circular cross-section and used to hold the moist web of paper in contact with the heated drying cylinders conceivably giving rise to marking of the web of paper whereas the flatter spirals hereinproposed would not only be less likely to give rise to marking but the more intimate contact with the drying cylinders could be expected to give an improvement in heat transmission and hence a more rapid and economical drying of the paper web. A further advantage will arise on fast running papermaking machines, in that the smoother surface will carry less boundary air and will thus be less likely to cause turbulence and possible fracture of the paper web.
It is to be observed that in forming a helical coil by winding a monofilament yarn of synthetic plastics material onto a mandrel the material may be deformed slightly at the ends of the major dimension of the coil cross section, the deformation being less in the case of coils wound from yarns of non-circular cross-section. Tests have shown that such latter coils exhibit a significantly lesser tendency to fibrillation in hydrolysis conditions than do comparable coils produced from circular cross-section yarns, although it has not been established whether any relationship exists between deformation and fibrillation. The reduced tendency to fibrillation apparent in the case of coils produced from yarns of non-circular cross-section results in a link belt of significantly improved resistance to belt breakage as compared with belts comprising coils wound from monofilament yarns of circular cross-section, thus giving a further benefit from the use of elongate synthetic plastics material of non-circular cross-section.
It is to be understood that, although specific mention has hereinbefore been made only of monofilament yarns, such expression is intended to include within its scope such as a resin treated multifilament yarn of equivalent or like characteristics and is, wherever the context so permits, to be construed accordingly. Indeed, the invention also includes any elongate synthetic plastics material of non-circular cross-section which comprises a core of circular or non-circular cross-section and a sheath or cover, say of polyamide, applied thereto. | The invention proposes the use, in the manufacture of link belts, of helical coils wound from elongate synthetic plastics material of non-circular, and preferably generally rectangular, transverse cross-section, the major dimension of the said cross-section extending widthwise of the link belt.
By using, for example, flat monofilament yarns of a given cross-section in the production of an oval coil of a related major dimension it is possible to increase the cross-section of the wire receiving tunnel formed by two interdigitated coils without prejudice to the capability of interdigitated coils to remain in mutual engagement, and thus facilitate the introduction of hinge wires by mechanical means. | 3 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This patent document claims priority to earlier filed U.S. Provisional Patent Application Ser. No. 61/536,642, filed on Sep. 20, 2011, the entire contents of which are incorporated herein by reference.
BACKGROUND
[0002] 1. Technical Field
[0003] The present patent document relates generally to an apparatus for converting the energy of wave motion on the surface of a body of water to electricity.
[0004] 2. Background of the Related Art
[0005] Generating electricity via ocean waves is a renewable energy source that has yet to be fully realized. Because ocean wave energy represents an unlimited, clean, renewable energy source, harnessing it is highly desirable to power our modern society.
[0006] Prior ocean wave energy converters, such as Ames, U.S. Pat. Nos. 4,232,230; 4,672,222; and 7,352,073 (incorporated herein by reference), although revolutionary in concept and design, suffer from several limitations. The '073 patent, in particular, includes a generator that rotates with magnets and coils, but problems with the arrangement include (1) a requirement for commutation brushes that become worn or compromised in the marine environment and (2) difficulty in adjusting coil properties due to their motion.
[0007] Also because wave energy converters are generally deployed in the ocean, they must be securely anchored lest they become navigation hazards or get damaged. However, traditional mooring methods involve setting multiple lines or fixed columns to the sea floor. This method is very costly, difficult and dangerous as it involves expensive equipment and possibly diving to depths of the ocean with all the known hazards thereof.
[0008] Therefore, there is a perceived need in the industry for an improved generator that lacks commutation brushes and an ability to adjust load properties during use. Furthermore is desirable to have a less costly method of anchoring the energy converters to the sea floor that minimizes the time that divers and submersibles must be used.
SUMMARY
[0009] The present invention solves the problems of the prior art by providing an improved generator that includes counter-rotating magnet rings of weight and size efficiently correlating to ratio between upstroke buoyancy force and downstroke gravity force. Furthermore, the coils are fixed thereby eliminating brushes, and allowing easier incorporation of shields and/or weather-proof housing. Additionally, switch components are more readily affixed to stationary coils, than moving coils, so that some coils may be taken out of circuit. The coils are further configured to be isolated from the circuit sot that the load on the buoy may be adjusted, resulting in near fully submerged buoy that more precisely follows complex waves while also providing maximal buoyancy force for power take-off. Finally, the counter-rotating magnet rotors add velocities together to increase polarity switch rate affecting coils.
[0010] In addition, the mooring system includes a plurality of mooring lines conjoined to terminals, at various intervals of lower depth, thereby resulting in fewer anchor points than if lines were not conjoined. Mooring line terminals may simply comprise knotting of the disparate lines but such assembly does not obviate forces that may limit mooring line flexibility when exposed to tensile forces. In a preferred embodiment, the mooring lines are conjoined, at successively lower levels, to terminate at singular anchor points. Because the number of lines decreases at each depth level, the time needed for divers and submersibles for repair, maintenance and installation is significantly reduced compared to traditional multi-line mooring techniques.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] These and other features, aspects, and advantages of the present invention will become better understood with reference to the following description, appended claims, and accompanying drawings where:
[0012] FIG. 1 is a perspective view of a preferred embodiment of the ocean wave energy converter of the present invention;
[0013] FIG. 2 is a partial cross-section view of FIG. 2 ;
[0014] FIG. 3 is a top cross-section view of the gearbox and generator;
[0015] FIG. 4 is a side cross-section view of the generator;
[0016] FIG. 5 is a exploded view of a buoy showing how the upper and lower shells stack together and the superstructure is assembled; and
[0017] FIG. 6 is a method of mooring the ocean wave energy converters of the present invention to the sea floor.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0018] Referring to FIGS. 1 and 2 , the ocean wave energy converter assembly of the present invention is shown generally at 10 . As will be more fully described below, the assembly of the present invention includes three tubular framing members 20 positioned in a tetrahedral arrangement that has a main body member 12 connected at the apex of the tetrahedron. Each of the tubular framing members 20 contains a drive rod 22 slidably received therein. Each drive rod 22 is respectively connected to its own buoy 249 . The assembly 10 of the present invention can be scaled appropriately to an optimal size for the known conditions or factors at the desired deployment site, such as average wave height, historical maximum wave height, depth of water, strength of currents, etc. One skilled in the art would appreciate how to select the parts and materials to construct an assembly of the present invention of the desired size.
[0019] The main body member 12 of the assembly 10 includes a top shell 14 and a bottom shell 16 . The top shell 14 and bottom shell 16 are secured together around a chassis to form a water-tight inner cavity to contain the generator 18 and ballast control components. Each shell 14 , 16 is lined with structural foam or other buoyant material to neutralize the buoyancy of the chassis, strengthen the material forming the shells 14 , 16 , and insulate the components contained therein.
[0020] Each assembly 10 includes three tubular framing members 20 that are arranged in a cone structure or more specifically as edges of the sides of a tetrahedron. The tubular framing members 20 connect to the main body 12 member, forming the apex of the tetrahedron. The tubular framing members 20 attach to the chassis of the module 10 and may be split into sections above and below the chassis. Each tubular framing member 20 contains a drive rod 22 , which is provided at its upper end with a buoy 24 . The tubular framing members 20 terminate at tube base connectors 26 securing them to frame members 28 which may form an equilateral triangle. A damper plate may be supported between the frame members 28 . Although it is preferred that the arrangement of the tubular framing members 20 is tetrahedral, other geometric-shaped arrangements could be used and would be effective. The base connectors 26 may include optional casters 30 to facilitate transportation, deployment and recovery of the assembly.
[0021] Contained within the terminal end of each tubular framing member 20 is a lower shock absorber 32 . The lower shock absorber 32 receives the downward stroke of its respective drive rod 22 . The lower shock absorber 32 reduces the stress on the assembly 10 and prepares the drive rod 22 for its upward stroke as it upwardly urges the drive rod 22 . At the upper end of each tubular member 20 is an upper shock absorber 34 . The upper shock absorber 34 provides an upper travel limit to the upward stroke of its respective drive rod 22 . The upper shock absorber 34 reduces the stress on the assembly 10 , and prepares the drive rod 22 for its downward stroke as it downwardly urges the drive rod 22 . Both the lower shock absorber 32 and upper shock absorber 34 are preferably non-metallic springs, but metal or other compressible materials could be used as appropriate for the size of the assembly in question. It is important to note that the upper and lower shock absorbers 32 , 34 will not be engaged regularly. In a typical deployment the module 10 are sized for deployment in an environment with wave size complimentary to the size of the module 10 . The shock absorbers 32 , 34 provide a mechanism to reduce stress and wear on the module during heavy seas.
[0022] The tubular framing members 20 serve respectively as guides or sleeves for a drive rod 22 contained therein. The drive rods 22 each have a rack 36 secured to the length of the drive rod 22 that passes through a gear box section of the main body member 12 . The rack 36 has teeth thereon, which engage and drive a gear 38 in the gear box section (described below). The drive rods 22 also may be partially or wholly filled with foam, or other buoyant material, to neutralize the buoyancy of the drive rod 22 , thereby enhancing the buoyancy of the buoy 24 . A secondary shock absorber 40 is attached to the lower end of the drive rod 22 . The secondary shock absorber 40 of the drive rod 22 works in conjunction with the upper shock absorber 34 in the respective tubular framing member 20 to limit the upward travel of the drive rod 22 and reduce the stress thereon.
[0023] Referring to FIGS. 3 and 4 , a close up view of the gear box section and generator 18 of the main body member 12 of the preferred embodiment are shown in detail. As the gear 38 is driven by the drive rod 22 , the gear 38 drives an axle 42 which is rotatably mounted within an axle brackets 44 . The axle 42 extends through a double labyrinth seal 46 and through a bushing 48 and into a generator 18 . The opposite end of the axle 42 is supported by a bushing 48 and axle bracket 44 . Although a double labyrinth seal is preferred, other seals could be used. Bearings may be included to smooth the rotation action on the axle 42 . Optional bushings may also be included to dampen any vibration generated by the general operation of the assembly.
[0024] The generator 18 includes an inner rotor 50 , a counter-rotating outer rotor 52 , and a stationary ring 54 positioned between then inner and outer rotors 50 , 52 . The inner rotor 50 is preferably constructed of a circular array of sixteen permanent magnets 56 , although other numbers of magnets could be used. The outer rotor 52 is preferably constructed of a circular array of eighteen permanent magnets 58 , although other numbers of magnets could be used. A number of T-shaped brackets 60 may be used to arrange the magnets concentrically about each rotor 50 , 52 . The inner rotor 50 and outer rotor 52 may also be formed from electromagnets as well, thereby making the generator 18 an alternator instead. The stationary ring 54 is constructed of one or more coils 62 , preferably seventeen although sixteen or eighteen could be used, of a number of loops of wire having an input lead and an output lead. The stationary ring 54 is fixed in position within the generator 18 and does not rotate. Shielding 65 may be provided between each coil 64 .
[0025] A first pair of clutches 66 connects the inner rotor 50 to the axle 42 and allows the axle 42 to turn the inner rotor 50 in one direction only. A second pair of clutches 68 connects the outer rotor 52 to the axle 42 and allows the outer rotor 52 to only turn in the opposite direction of the inner rotor 50 . Rotational movement of the inner rotor 50 relative to stationary ring 18 induces electricity in the coils 62 and through leads 63 . Inducing electricity in a coil through use of a magnet is well-known in the art and does not need to be described in detail herein. The leads are connected to a cord 70 which carries the generated electricity to other modules or shore as described below.
[0026] In an alternative embodiment, the inner rotor and outer rotor of the generator are constructed of one or more coils of a number of loops of wire and the stationary ring is constructed of a circular array of permanent magnets. Thus, being the opposite of the preferred embodiment. If electromagnets are used in place of permanent magnets, load balancing may be accomplished by selectively energizing coils as is known in the art with alternators.
[0027] The inner cavity of the main body member 12 also includes an active ballast control system that includes a proportional controller 72 , a pump 74 , and three bladders 76 that are secured to the chassis. The proportional controller 72 measures the attitude and depth to the assembly 10 relative to mean sea level and generates control inputs to the pump 74 to keep the assembly at an optimum depth in the water. The pump 74 fills or evacuates the bladders 76 according to the inputs received from the proportional controller 72 . The bladders 76 are fashioned of a non-porous flexible material that is easily deformed. The pump 74 is connected by wires to the cord 70 and are powered from excess electrical power generated by the generators 18 , but also could be easily supplemented from driveshaft motions or other optional sources such as an additional battery (not shown).
[0028] Pressure sensors may also be included in the inner cavity of the main body member 12 and in the buoys 24 and may be used to send control data to the pump 74 and bladders 76 for adjusting the assembly attitude. It may be desirable to have assemblies 10 raised or lowered, in relation to waves, for maintaining optimal buoy stroke (too high or low results in reduced buoy action). The sensor data form the inner cavity data integrates with the buoy pressure data. Buoy input to controls may be from pressure sensors located at buoy's lower shell. These sensors provide data to a control matrix of an array of assemblies. That is, individual buoy movements contribute to mapping entire wave fields engaging an array. “Downwave” modules use data for predicting wave action, interference, cancellation that are likely to engage them and optimally pre-adjust the generator “just-in-time”. The result at most times enables near fully submerged, wave-following buoys (most buoyancy force and driveshaft travel length responding to subject wave).
[0029] Housed in the inner cavity of the main body 12 , a control system may incorporate sensor networks including pressure sensors in the buoy 24 . Due to independent buoy 24 motions, an associated sensor would require wireless data transmission to buoyancy chamber controls and such radio transmission has possibly deleterious effect to marine bio-forms. Improved sensing means are contained in the inner cavity, only, within and between which inner cavity walls and structural foam is provided signal attenuating liner thereby reducing or eliminating external signal transmission.
[0030] Sensing means comprise non-contacting proximity sensor, associated with the axle 42 , which counts revolution quantity, velocity, and direction relative to start position. Axle 42 and sensor zero stage may be neutrally located near mid-point, between a buoy and drive rod 22 fully extended and retracted positions, and thus deviations from zero stage indicate buoy 24 and drive rod 22 position. A number of such sensors, associated with respective buoys of a plurality of assemblies, form composite data of the positions of all buoys 24 of an array and, thus, a wave by wave profile of the ambient seascape. Sequential updates provide predictors for assessment of wave field motions, for example, by combining disparate geographic data points that may indicate the eventual creation or dissipation of interference wave amplitudes at specific positions in the future. Such data is incorporated in the control system to precisely adjust generator properties just-in-advance of incoming waves. A desirable feature is expressed when a buoy 24 follows a wave surface, while remaining near full submergence, utilizing maximal buoyancy force and axle 42 travel length to power electrical generators 18 .
[0031] Buoy wave-following capability is affected by generator 18 loads expressed through the rack and pinion motion converter. Large loads may induce back-forces into the system that stall, or even stop, buoy motion. While this condition is desirable in module servicing or certain stages of power extraction, for example, to hold down buoy in submerged position for eventual release in approaching wave crests or to hold up buoy in overly energetic wave conditions, also desirable is to control such features. For such purpose, generator coil segments are separable, by switches, from the coils in the stationary ring thereby enabling individual segments to be taken out of loop and diverting the electromotive force affecting the assembly. In effect, the variably exerted generator loads may incorporate with buoy sensing means to thereby form precise control topology for improving the operation and electrical output of a module array.
[0032] At times a module 10 may raise or lower to disadvantageous position due to environmental influences such as wave activity or changes of water temperature. At such instance is desirable for the module 10 to reposition at attitudes promoting optimal buoy 24 and drive rod 22 operation. For the purpose, buoyancy chamber pressure sensor indicates its position relative to the hydroface. When a module 10 sinks or floats out of range of optimal operational positions, pumps 74 are activated to introduce seawater to or expel seawater from bladders 76 thereby adjusting buoyancy of the chamber.
[0033] Referring to FIGS. 1 , 2 and 5 , each buoy 24 includes an upper shell 80 and a lower shell 82 . The upper shell 80 and the lower shell 82 are secured together with rivets 84 , or other suitable fasteners, around a superstructure 86 to form a water-tight chamber, thereby making the buoy 24 highly buoyant. The upper shell 80 optionally includes an eyebolt 88 to assist in assembling, deployment and recovery of the assembled buoys 24 . The superstructure 86 includes a radial cuff 90 that primarily supports and strengthens the upper and lower shells 80 , 82 . Internal braces 92 are secured within the chamber of the upper and lower shells 80 , 82 to give the buoy 24 added strength and rigidity. The internal braces 92 are attached the drive rod 22 and radial cuff 90 . Each shell 80 , 82 is lined with foam or other buoyant material to neutralize the buoyancy of material forming the shells 80 , 82 and the internal braces 92 container therein, thereby enhancing the buoyancy effect of the empty chamber.
[0034] One end of the drive rod 22 is passed through an aperture 94 on the lower 82 shell and secured to the upper shell 80 . Optional bracing elements 96 are secured to around the drive rod 22 and to the lower shell 82 to reduce the strain on the lower shell 82 and drive rod 22 from the force of the waves impacting the buoy 24 . Prior to deployment of the assembly, the unassembled shells 80 , 82 of the buoys 24 may be stacked together for ease of storage and transportation to the deployment site.
[0035] The buoy 24 upper and lower shells 80 , 82 have a conical shape with a circular cross-section and, together, they form a tetras. This tetras shape has been found to be optimal to smooth fluid flow about the buoy 24 in order to maximize stroke power, yet minimize rotational torque on the generator 18 assembly, thereby increasing the lifespan of the mechanical components.
[0036] In operation, the assembly 10 floats in a body of water with the buoys 24 partially submerged at the surface, and the remaining part of the assembly 10 submerged in the water. As each wave passes, the buoys 24 are raised and lowered moving the drive rods 22 in the tubular framing members 20 . The motion of a drive rod 22 drives the counter-rotating portions of the generator 18 . Each buoy/drive rod combination drives its own generator 18 . The sum-total electrical output of an array of modules 10 may be transported to shore by an umbilical cord 70 or used to power an accessory module for desalination or hydrogen production operations. Each assembly 10 forms a module that can be interconnected to other modules to form an ocean wave energy web or matrix to mass produce electricity. The ocean wave energy web is capable of being deployed throughout the bodies of water of the world.
[0037] Referring now to FIG. 6 , arrays 100 generally form neutrally buoyant, horizontal planes near below the hydroface 101 . Typically of breadth spanning multiple wavelengths, in most instances some array 100 portions are influenced by downward gravity forces from wave troughs while other portions are influenced by upward buoyancy force from buoys 24 and buoyancy chambers. Buoy drive shafts 22 freely travel, with only contacting tube bearings, and forces exerted on the truss tend to cancel out thereby having negligible effect on truss attitude. At times, however, large waves exert correspondingly higher forces, above operational range, causing extension of buoy drive shafts 22 to positions in contact with shock absorption means contained in tubular framing members 20 .
[0038] At such instant buoys 24 and module 10 lower portions become more dependent systems than in normal operating conditions. These vertical forces, while efficiently distributed in the truss matrix, tend to be greatly dissipated in the water column by optional damper plate horizontally disposed between lower module framing members 28 .
[0039] The self-stabilizing feature thus requires only light bottom, slack mooring. Examination of module array 100 mooring determined that relatively few mooring attachment points are required to be distributed among a module array 100 for keeping a module array 100 on station. Portions of the mooring lines 102 , when conjoined and extended from terminals 104 at some depth below hydroface 101 , perform efficiently in similar manner to laid rope for coalescing mooring stresses and inherently increasing tensile strength.
[0040] In large module arrays 100 , deployed in deeper water, a plurality of such mooring lines 102 may in similar fashion be conjoined to terminals 104 , at various intervals of lower depth, thereby resulting in fewer anchor points 106 to the seafloor 108 than if lines 102 were not conjoined. Mooring line terminals 104 may simply comprise knotting of the disparate lines 102 but such assembly does not obviate forces that may limit mooring line 102 flexibility when exposed to tensile forces. An improved mooring junction comprises box, with top and bottom opening, supporting spring-loaded reels. Lines 102 are wrapped on reels to some extent providing sufficient pay-out or take-up for maintaining sufficient tension that reduces line 102 sagging and shock loads exerted on truss modules 10 .
[0041] It would be appreciated by those skilled in the art that various changes and modifications can be made to the illustrated embodiments without departing from the spirit of the present invention. All such modifications and changes are intended to be within the scope of the present invention. | An apparatus for converting the kinetic energy of ocean waves into electricity is disclosed. The apparatus includes a main body member. A generator is located within the main body member. The generator includes a axle having a positive direction and a negative direction. An inner rotor is driven by the axle, wherein the inner rotor is driven only in the negative direction of the axle. An outer rotor surrounds the inner rotor and is also being driven by the axle, wherein the outer rotor is driven only in the positive direction of the driveshaft. A stationary ring is located between the inner rotor and the outer rotor. A drive rod, having a buoy attached to one end, is configured to freely move between an upstroke position and a downstroke position. The drive rod drives the generator as it reciprocates between the upstroke position and the downstroke position. | 5 |
[0001] This is a divisional application of U.S. patent application Ser. No. 10/676,269, filed on Oct. 2, 2003. The disclosure of the prior application is hereby incorporated by reference in its entirety.
FIELD OF INVENTION
[0002] The present invention relates to speech encoding in a communication system.
BACKGROUND TO THE INVENTION
[0003] Cellular communication networks are commonplace today. Cellular communication networks typically operate in accordance with a given standard or specification. For example, the standard or specification may define the communication protocols and/or parameters that shall be used for a connection. Examples of the different standards and/or specifications include, without limiting to these, GSM (Global System for Mobile communications), GSM/EDGE (Enhanced Data rates for GSM Evolution), AMPS (American Mobile Phone System), WCDMA (Wideband Code Division Multiple Access) or 3rd generation (3G) UMTS (Universal Mobile Telecommunications System), IMT 2000 (International Mobile Telecommunications 2000) and so on.
[0004] In a cellular communication network, voice data is typically captured as an analogue signal, digitised in an analogue to digital (A/D) converter and then encoded before transmission over the wireless air interface between a user equipment, such as a mobile station, and a base station. The purpose of the encoding is to compress the digitised signal and transmit it over the air interface with the minimum amount of data whilst maintaining an acceptable signal quality level. This is particularly important as radio channel capacity over the wireless air interface is limited in a cellular communication network. The sampling and encoding techniques used are often referred to as speech encoding techniques or speech codecs.
[0005] Often speech can be considered as bandlimited to between approximately 200 Hz and 3400 Hz. The typical sampling rate used by a A/D converter to convert an analogue speech signal into a digital signal is either 8 kHz or 16 kHz. The sampled digital signal is then encoded, usually on a frame by frame basis, resulting in a digital data stream with a bit rate that is determined by the speech codec used for encoding. The higher the bit rate, the more data is encoded, which results in a more accurate representation of the input speech frame. The encoded speech can then be decoded and passed through a digital to analogue (D/A) converter to recreate the original speech signal.
[0006] An ideal speech codec will encode the speech with as few bits as possible thereby optimising channel capacity, while producing decoded speech that sounds as close to the original speech as possible. In practice there is usually a trade-off between the bit rate of the codec and the quality of the decoded speech.
[0007] In today's cellular communication networks, speech encoding can be divided roughly into two categories: variable rate and fixed rate encoding.
[0008] In variable rate encoding, a source based rate adaptation (SBRA) algorithm is used for classification of active speech. Speech of differing classes are encoded by different speech modes, each operating at a different rate. The speech modes are usually optimised for each speech class. An example of variable rate speech encoding is the enhanced variable rate speech codec (EVRC).
[0009] In fixed rate speech encoding, voice activity detection (VAD) and discontinuous transmission (DTX) functionality is utilised, which classifies speech into active speech and silence periods. During detected silence periods, transmission is performed less frequently to save power and increase network capacity. For example, in GSM during active speech every speech frame, typically 20 ms in duration, is transmitted, whereas during silence periods, only every eighth speech frame is transmitted. Typically, active speech is encoded at a fixed bit rate and silence periods with a lower bit rate.
[0010] Multi-rate speech codecs, such as the adaptive multi-rate (AMR) codec and the adaptive multi-rate wideband (AMR-WB) codec were developed to include VAD/DTX functionality and are examples of fixed rate speech encoding. The bit rate of the speech encoding, also known as the codec mode, is based factors such as the network capacity and radio channel conditions of the air interface.
[0011] AMR was developed by the 3 rd Generation Partnership Project (3GPP) for GSM/EDGE and WCDMA communication networks. In addition, it has also been envisaged that AMR will be used in future packet switched networks. AMR is based on Algebraic Code Excited Linear Prediction (ACELP) coding. The AMR and AMR WB codecs consist of 8 and 9 active bit rates respectively and also include VAD/DTX functionality. The sampling rate in the AMR codec is 8 kHz. In the AMR WB codec the sampling rate is 16 kHz.
[0012] ACELP coding operates using a model of how the signal source is generated, and extracts from the signal the parameters of the model. More specifically, ACELP coding is based on a model of the human vocal system, where the throat and mouth are modelled as a linear filter and speech is generated by a periodic vibration of air exciting the filter. The speech is analysed on a frame by frame basis by the encoder and for each frame a set of parameters representing the modelled speech is generated and output by the encoder. The set of parameters may include excitation parameters and the coefficients for the filter as well as other parameters. The output from a speech encoder is often referred to as a parametric representation of the input speech signal. The set of parameters is then used by a suitably configured decoder to regenerate the input speech signal.
[0013] Details of the AMR and AMR-WB codecs can be found in the 3GPP TS 26.090 and 3GPP TS 26.190 technical specifications. Further details of the AMR-WB codec and VAD can be found in the 3GPP TS 26.194 technical specification. All the above documents are incorporated herein by reference.
[0014] Both AMR and AMR-WB codecs are multi rate codecs with independent codec modes or bit rates. In both the AMR and AMR-WB codecs, the mode selection is based on the network capacity and radio channel conditions. However, the codecs may also be operated using a variable rate scheme such as SBRA where the codec mode selection is further based on the speech class. The codec mode can then be selected independently for each analysed speech frame (at 20 ms intervals) and may be dependent on the source signal characteristics, average target bit rate and supported set of codec modes. The network in which the codec is used may also limit the performance of SBRA. For example, in GSM, the codec mode can be changed only once every 40 ms.
[0015] By using SBRA, the average bit rate may be reduced without any noticeable degradation in the decoded speech quality. The advantage of lower average bit rate is lower transmission power and hence higher overall capacity of the network.
[0016] Typical SBRA algorithms determine the speech class of the sampled speech signal based on speech characteristics. These speech classes may include low energy, transient, unvoiced and voice sequences. The subsequent speech encoding is dependent on the speech class. Therefore, the accuracy of the speech classification is important as it determines the speech encoding and associated encoding rate. In previously known systems, the speech class is determined before speech encoding begins.
[0017] Furthermore, the AMR and AMR-WB codecs may utilise SBRA together with VAD/DTX functionality to lower the bit rate of the transmitted data during silence periods. During periods of normal speech, standard SBRA techniques are used to encode the data. During silence periods, VAD detects the silence and interrupts transmission (DTX) thereby reducing the overall bit rate of the transmission.
[0018] Although effective, SBRA algorithms are very complex and require a large amount of memory and resources to implement. As such, their usage has so far been limited due to the substantial overheads.
[0019] It is the aim of embodiments of the present invention to provide an improved speech encoding method that at least partly mitigates some of the above problems.
SUMMARY OF THE INVENTION
[0020] In accordance with an embodiment, a method is provided including receiving a frame at a voice activity detection module, and determining, at the voice activity detection module, a first set of parameters from the frame. The method also includes providing the first set of parameters to a codec mode selection module, and determining, at the codec mode selection module, a second set of parameters in dependence on the first set of parameters. The method further includes selecting a codec mode to encode the frame at the codec mode selection module in dependence on the second set of parameters.
[0021] In accordance with another embodiment, an apparatus is provided including a voice activity detection module configured to detect silent frames, and a codec mode selection module configured to determine a codec mode. The voice activity detection module includes a receiver configured to receive a frame, a first determiner configured to determine a first set of parameters from the frame, and a provider configured to provide the first set of parameters to the codec mode selection module. The codec mode selection module includes a second determiner configured to determine a second set of parameters in dependence on the first set of parameters, and a selector configured to select a codec mode in dependence on the second set of parameters.
[0022] In accordance with another embodiment, an apparatus is provided including voice activity detection means for detecting silent frames, and codec mode selection means for determining a codec mode. The voice activity detection means includes receiving means for receiving a frame, first determining means for determining a first set of parameters from the frame, and providing means for providing the first set of parameters to the codec mode selection means. The codec mode selection means includes second determining means for determining a second set of parameters in dependence on the first set of parameters, and selecting means for selecting a codec mode in dependence on the second set of parameters.
BRIEF DESCRIPTION OF DRAWINGS
[0023] For a better understanding of the present invention reference will now be made by way of example only to the accompanying drawings, in which:
[0024] FIG. 1 illustrates a communication network in which embodiments of the present invention can be applied;
[0025] FIG. 2 illustrates a block diagram of a prior art arrangement;
[0026] FIG. 3 illustrates a signal flow diagram of an arrangement of the prior art;
[0027] FIG. 4 illustrates a bit allocation table of coding modes in a preferred embodiment of the present invention;
[0028] FIG. 5 illustrates a block diagram of a preferred embodiment of the present invention;
[0029] FIG. 6 illustrates a signal flow diagram of an arrangement of a preferred embodiment of the present invention; and
[0030] FIG. 7 illustrates a block diagram of a further embodiment of the present invention.
DETAILED DESCRIPTION OF EMBODIMENTS
[0031] The present invention is described herein with reference to particular examples. The invention is not, however, limited to such examples.
[0032] FIG. 1 illustrates a typical cellular telecommunication network 100 that supports an AMR speech codec. The network 100 comprises various network elements including a mobile station (MS) 101 , a base transceiver station (BTS) 102 and a transcoder (TC) 103 . The MS communicates with the BTS via the uplink radio channel 113 and the downlink radio channel 126 . The BTS and TC communicate with each other via communication links 115 and 124 . The BTS and TC form part of the core network. For a voice call originating from the MS, the MS receives speech signals 110 at a multi-rate speech encoder module 111 .
[0033] In this example, the speech signals are digital speech signals converted from analogue speech signals by a suitably configured analogue to digital (A/D) converter (not shown). The multi-rate speech encoder module encodes the digital speech signal 110 into a speech encoded signal on a frame by frame basis, where the typical frame duration is 20 ms. The speech encoded signal is then transmitted to a multi-rate channel encoder module 112 . The multi-rate channel encoder module further encodes the speech encoded signal from the multi-rate speech encoder module. The purpose of the multi-rate channel encoder module is to provide coding for error detection and/or error correction purposes. The encoded signal from the multi-rate channel encoder is then transmitted across the uplink radio channel 113 to the BTS. The encoded signal is received at a multi-rate channel decoder module 114 , which performs channel decoding on the received signal. The channel decoded signal is then transmitted across communication link 115 to the TC 103 . In the TC 103 , the channel decoded signal is passed into a multi-rate speech decoder module 116 , which decodes the input signal and outputs a digital speech signal 117 corresponding to the input digital speech signal 110 .
[0034] A similar sequence of steps to that of a voice call originating from a MS to a TC occurs when a voice call originates from the core network side, such as from the TC via the BTS to the MS. When the voice calls starts from the TC, the speech signal 122 is directed towards a multi-rate speech encoder module 123 , which encodes the digital speech signal 122 . The speech encoded signal is transmitted from the TC to the BTS via communication link 124 . At the BTS, it is received at a multi-rate channel encoder module 125 . The multi-rate channel encoder module 125 further encodes the speech encoded signal from the multi-rate speech encoder module 123 for error detection and/or error correction purposes. The encoded signal from the multi-rate channel encoder module is transmitted across the downlink radio channel 126 to the MS. At the MS, the received signal is fed into a multi-rate channel decoder module 127 and then into a multi-rate speech decoder module 128 , which perform channel decoding and speech decoding respectively. The output signal from the multi-rate speech decoder is a digital speech signal 129 corresponding to the input digital speech signal 122 .
[0035] Link adaptation may also take place in the MS and BTS. Link adaptation selects the AMR multirate speech codec mode according to transmission channel conditions. If the transmission channel conditions are poor, the number of bits used for speech encoding can be decreased (lower bit rate) and the number of bits used for channel encoding can be increased to try and protect the transmitted information. However, if the transmission channel conditions are good, the number of bits used for channel encoding can be decreased and the number of bits used for speech encoding increased to give a better speech quality.
[0036] The MS may comprise a link adaptation module 130 , which takes data 140 from the downlink radio channel to determine a preferred downlink codec mode for encoding the speech on the downlink channel. The data 140 is fed into a downlink quality measurement module 131 of the link adaptation module 130 , which calculates a quality indicator message for the downlink channel, QI d . QI d is transmitted from the downlink quality measurement module 131 to a mode request generator module 132 via connection 141 . Based on QI d , the mode request generator module 132 calculates a preferred codec mode for the downlink channel 126 . The preferred codec mode is transmitted in the form of a codec mode request message for the downlink channel MR d to the multi-rate channel encoder 112 module via connection 142 . The multi-rate channel encoder 112 module transmits MR d through the uplink radio channel to the BTS.
[0037] In the BTS, MR d may be transmitted via the multi-rate channel decoder module 114 to a link adaptation module 133 . Within the link adaptation module in the BTS, the codec mode request message for the downlink channel MR d is translated into a codec mode request message for the downlink channel MC d . This function may occur in the downlink mode control module 120 of the link adaptation module 133 . The downlink mode control module transmits MC d via connection 146 to communications link 115 for transmission to the TC.
[0038] In the TC, MC d is transmitted to the multi-rate speech encoder module 123 via connection 147 . The multi-rate speech encoder module 123 can then encode the incoming speech 122 with the codec mode defined by MC d . The encoded speech, encoded with the adapted codec mode defined by MC d , is transmitted to the BTS via connection 148 and onto the MS as described above. Furthermore, a codec mode indicator message for the downlink radio channel MI d may be transmitted via connection 149 from the multi-rate speech encoder module 123 to the BTS and onto the MS, where it is used in the decoding of the speech in the multi-rate speech decoder 127 at the MS.
[0039] A similar sequence of steps to link adaptation for the downlink radio channel may also be utilised for link adaptation of the uplink radio channel. The link adaptation module 133 in the BTS may comprise an uplink quality measurement module 118 , which receives data from the uplink radio channel and determines a quality indicator message, QI u , for the uplink radio channel. QI u is transmitted from the uplink quality measurement module 118 to the uplink mode control module 119 via connection 150 . The uplink mode control module 119 receives QI u together with network constraints from the network constraints module 121 and determines a preferred codec mode for the uplink encoding. The preferred codec mode is transmitted from the uplink control module 119 in the form of a codec mode command message for the uplink radio channel MC u to the multi-rate channel encoder module 125 via connection 151 . The multi-rate channel encoder module 125 transmits MC u together with the encoded speech signal over the downlink radio channel to the MS.
[0040] In the MS, MC u is transmitted to the multi-rate channel decoder module 127 and then to the multi-rate speech encoder 111 via connection 153 , where it is used to determine a codec mode for encoding the input speech signal 110 . As with the speech encoding for the downlink radio channel, the multi-rate speech coder module for the uplink radio channel generates a codec mode indicator message for the uplink radio channel MI u . MI u is transmitted from the multi-rate speech encoder control module 111 to the multi-rate channel encoder module 112 via connection 154 , which in turn transmits MI u via the uplink radio channel to the BTS and then to the TC. MI u is used at the TC in the multi-rate speech decoder module 116 to decode the received encoded speech with a codec mode determined by MI u .
[0041] FIG. 2 illustrates a block diagram of the multi-rate speech encoder module 111 and 123 of FIG. 1 in the prior art. The multi-rate speech encoder module 200 may operate according to an AMR-WB codec and comprise a voice activity detection (VAD) module 202 , which is connected to both a source based rate adaptation (SBRA) algorithm module 203 and a discontinuous transmission (DTX) module 205 . The VAD module receives a digital speech signal 201 and determines whether the signal comprises active speech or silence periods. During a silence period, the DTX module is activated and transmission interrupted for the duration of the silence period. During periods of active speech, the speech signal may be transmitted to the SBRA algorithm module. The SBRA algorithm module is controlled by the RDA module 204 . The RDA module defines the used average bit rate in the network and sets the target average bit rate for the SBRA algorithm module. The SBRA algorithm module receives speech signals and determines a speech class for the speech signal based on its speech characteristics. The SBRA algorithm module is connected to a speech encoder 206 , which encodes the speech signal received from the SBRA algorithm module with a codec mode based on the speech class selected by the SBRA algorithm module. The speech encoder operates using Algebraic Code Excited Linear Prediction (ACELP) coding.
[0042] The codec mode selection may depend on many factors. For example, low energy speech sequences may be classified and coded with a low bit rate codec mode without noticeable degradation in speech quality. On the other hand, during transient sequences, where the signal fluctuates, the speech quality can degrade rapidly if codec modes with lower bit rates are used. Coding of voiced and unvoiced speech sequences may also be dependent on the frequency content of the sequence. For example, a low frequency speech sequence can be coded with a lower bit rate without speech quality degradation, whereas high frequency voice and noise-like, unvoiced sequences may need a higher bit rate representation.
[0043] The speech encoder 206 in FIG. 2 comprises a linear prediction coding (LPC) calculation module 207 , a long term prediction (LTP) calculation module 208 and a fixed code book excitation module 209 . The speech signal is processed by the LPC calculation module, LTP calculation module and fixed code book excitation module on a frame by frame basis, where each frame is typically 20 ms long. The output of the speech encoder consists of a set of parameters representing the input speech signal.
[0044] Specifically, the LPC calculation module 207 determines the LPC filter corresponding to the input speech frame by minimising the residual error of the speech frame. Once the LPC filter has been determined, it can be represented by a set of LPC filter coefficients for the filter.
[0045] The LPC filter coefficients are quantized by the LPC calculation module before transmission. The main purpose of quantization is to code the LPC filter coefficients with as few bits as possible without introducing additional spectral distortion. Typically, LPC filter coefficients, {a 1 , . . . , a p }, are transformed into a different domain, before quantization. This is done because direct quantization of the LPC filter, specifically an infinite impulse response (IIR) filter, coefficients may cause filter instability. Even slight errors in the IIR filter coefficients can cause significant distortion throughout the spectrum of the speech signal.
[0046] The LPC calculation module coverts the LPC filter coefficients into the immitance spectral pair (ISP) domain before quantization. However, the ISP domain coefficients may be further converted into the immitance spectral frequency (ISF) domain before quantization.
[0047] The LTP calculation module 208 calculates an LTP parameter from the LPC residual. The LTP parameter is closely related to the fundamental frequency of the speech signal and is often referred to as a “pitch-lag” parameter or “pitch delay” parameter, which describes the periodicity of the speech signal in terms of speech samples. The pitch-delay parameter is calculated by using an adaptive codebook by the LTP calculation module.
[0048] A further parameter, the LTP gain is also calculated by the LTP calculation module and is closely related to the fundamental periodicity of the speech signal. The LTP gain is an important parameter used to give a natural representation of the speech. Voiced speech segments have especially strong long-term correlation. This correlation is due to the vibrations of the vocal cords, which usually have a pitch period in the range from 2 to 20 ms.
[0049] The fixed code book excitation module 209 calculates the excitation signal, which represents the input to the LPC filter. The excitation signal is a set of parameters represented by innovation vectors with a fixed codebook combined with the LTP parameter. In a fixed codebook, algebraic code is used to populate the innovation vectors. The innovation vector contains a small number of nonzero pulses with predefined interlaced sets of potential positions. The excitation signal is sometimes referred to as algebraic codebook parameter.
[0050] The output from the speech encoder 210 in FIG. 2 is an encoded speech signal represented by the parameters determined by the LPC calculation module, the LTP calculation module and the fixed code book excitation module, which include:
[0000] 1. LPC parameters quantised in ISP domain describing the spectral content of the speech signal;
2. LTP parameters describing the periodic structure of the speech signal;
3. ACELP excitation quantisation describing the residual signal after the linear predictors.
4. Signal gain.
[0051] The bit rate of the codec mode used by the speech encoder may affect the parameters determined by the speech encoder. Specifically, the number of bits used to represent each parameter varies according to the bit rate used. The higher the bit rate, the more bits may be used to represent some or all of the parameters, which may result in a more accurate representation of the input speech signal.
[0052] FIG. 4 illustrates a bit allocation table for the codec modes in the AMR-WB codec. The table illustrates the number of bits required to represent the speech encoder parameters corresponding to the different codec modes. The columns indicate the codec modes: 6.60, 8.85, 12.65, 14.25, 15.85, 18.25, 19.85, 23.05 and 23.85 kbit/s. The rows indicate the parameters output by the encoder for each codec mode: a VAD flag, a LTP filtering flag, ISP, pitch delay, algebraic CB (codebook), gains and high-band energy. For example, the number of bits required for representing the LTP filtering flag parameter and the gain parameter when the 15.85 kbit/s codec mode is selected is 4 and 28 bits respectively.
[0053] The parameters illustrated in FIG. 4 represent the encoded speech signal, and each may be generated by the speech encoder or transmitted to the speech encoder before encoding begins. For example, the VAD flag may be set by the VAD module 202 before onward transmission to the speech encoder. The ISP parameter represents the LPC filter coefficients and is typically calculated by the LPC calculation module 207 . The LTP filtering flag parameter, the pitch delay parameter and the gain parameter are typically calculated by the LTP calculation module 208 . The algebraic CB parameter is typically calculated by the fixed codebook excitation module 209 . The high-band energy parameter represents the high band energy gain of the encoded speech signal.
[0054] All the parameters representing encoded speech signal may be transmitted to a speech decoder together with codec mode information for decoding of the encoded speech signal.
[0055] FIG. 3 is a signal flow diagram illustrating the processing for a speech frame taking place at the SBRA algorithm module and the speech encoder of FIG. 2 .
[0056] A speech frame 301 is processed by the SBRA algorithm module 340 , where a codec mode is selected prior to speech encoding. In this example, there are three codec modes: a first codec mode 341 , a second codec mode 342 and a third codec mode 343 . It should be appreciated that other codec modes may be present that are not illustrated in FIG. 3 .
[0057] For each codec mode, speech encoding is performed by a plurality of speech processing algorithm groups on the speech frame. There are N speech processing algorithm groups: speech processing algorithm group I, 302 , speech processing algorithm group II, 303 , and speech processing algorithm group N, 304 illustrated in FIG. 3 . It should be appreciated that other speech processing algorithm groups may be present that are not illustrated in FIG. 3 . Each of the speech processing algorithm groups perform one of LPC calculations, LTP calculations and excitation calculations and may be implemented in the LPC calculation module, LTP calculation module and fixed code book excitation module described in FIG. 2 .
[0058] Each speech algorithm group comprises a plurality of speech processing algorithms. Each speech processing algorithm may perform different calculations and/or calculate different speech encoding parameters. The speech encoding parameters calculated by each of the speech processing algorithms of a speech algorithm group may vary in their characteristics of bit size.
[0059] Speech processing algorithm group I comprises speech processing algorithm I-A, 310 , speech processing algorithm I-B, 320 , and speech processing algorithm I-C, 330 . Speech processing algorithm group II comprises speech processing algorithm II-A, 311 , speech processing algorithm II-B, 321 , and speech processing algorithm II-C, 331 . Speech processing algorithm group N comprises speech processing algorithm N-A, 312 , speech processing algorithm N-B, 322 , and speech processing algorithm N-C, 332 .
[0060] The selection of the codec mode at the SBRA algorithm module determines which of the speech processing algorithms are used to encode the speech frame. For example, in FIG. 3 , a speech frame using the first speech codec 341 is encoded by speech processing algorithm I-A, 310 , speech processing algorithm II-A, 311 , and speech processing algorithm N-A, 312 . A speech frame using the second speech codec 342 is encoded by speech processing algorithm I-B, 320 , speech processing algorithm II-B, 321 , and speech processing algorithm N-B, 322 . A speech frame using the third speech codec 343 is encoded by speech processing algorithm I-C, 330 , speech processing algorithm II-C, 331 , and speech processing algorithm N-C, 332 .
[0061] The encoded speech frame for the first codec mode is output as a parametric representation 313 . The encoded speech frame for the second codec mode is output as a parametric representation 323 . The encoded speech frame for the third codec mode is output as a parametric representation 333 .
[0062] The decision made by the SBRA algorithm module on which one of the codec modes to select fixes the speech algorithms used for processing the speech frame. This decision is made before speech encoding is started.
[0063] In a preferred embodiment of the present invention, the decision as to which speech codec mode to select is delayed. The delay to the decision is dependent on the speech encoder structure. The delay to the decision may result in a more accurate or appropriate selection of the codec mode compared to previously known methods such as those illustrated in FIGS. 2 and 3 above and the total processing required may also be reduced. Preferred embodiments of the present invention utilise a branched SBRA algorithm approach.
[0064] FIG. 5 illustrates a block diagram of a multi-rate speech encoder module 400 in a preferred embodiment of the present invention, wherein the codec mode selection is delayed. Preferably, though not essentially, the speech encoder may operate with the AMR-WB speech codec together with SBRA. Alternatively, the speech encoder may also operate with the AMR speech codec or other suitable speech codec.
[0065] The multi-rate speech encoder module 400 may comprise a voice activity detection (VAD) module 402 connected to a speech encoder 405 and a discontinuous transmission (DTX) module 403 . The VAD module receives a speech signal 401 and determines whether the speech signal comprises active speech or silence periods. During silence periods, the DTX module may be activated and onward transmission of the speech signal interrupted during the silence period. During periods of active speech, the speech signal may be transmitted to the speech encoder 405 .
[0066] The speech encoder 405 may comprise a linear predictive coding (LPC) calculation module 407 , a long term prediction (LTP) calculation module 407 and a fixed code book excitation module 411 . The speech signal received by the speech encoder is processed by the LPC calculation module, LTP calculation module and fixed code book excitation module on a frame by frame basis, where each frame is typically 20 ms long. Each of the modules of the speech encoder determine the parameters associated with the speech encoding process. The output of the speech encoder consists of a plurality of parameters representing the encoded speech frame.
[0067] It should be appreciated that the speech encoder module may comprise other modules not illustrated in FIG. 5 .
[0068] The speech encoder module 400 further comprises a source based rate adaptation (SBRA) algorithm module 404 . The SBRA algorithm module comprises a low mode selection module 406 , a middle mode selection module 408 and a high mode refinement module 410 .
[0069] The low mode selection module examines the speech signal sent from the VAD module to the LPC calculation module and performs calculations based on this speech signal. The middle mode selection module examines the data sent from the LPC calculation module to the LTP calculation module, which may comprise LPC parameters, such as ISP parameters, and other parameters, and performs calculations based on this data. The high mode refinement module examines the data sent from the LTP calculation module to the fixed codebook excitation module, which may comprise LPC parameters, such as pitch delay parameters, gain parameters and an LTP filtering flag parameter, LTP parameters and other parameters, and performs calculations based on this data.
[0070] The low mode selection module 406 , middle mode selection module 408 and high mode refinement module 410 are used to determine the codec mode for speech encoding. In a preferred embodiment of the invention, the AMR-WB codec is used and the codec modes available in AMR-WB are 6.60, 8.85, 12.65, 14.25, 15.85, 18.25, 19.85, 23.05 and 23.85 kbit/s.
[0071] Active speech signals are transmitted from the VAD module to the speech encoder 405 . The low mode selection module 406 examines the speech signal on a frame by frame basis and determines whether the lowest codec mode, in this example the 6.60 kbit/s codec mode, is to be used. The lowest codec mode may need to be determined before generation and quantisation of the LPC parameters, such as the an ISP parameter, by the LPC calculation module 407 , as the lowest codec mode may have a different LPC parameter characteristic compared with all other codec modes. In a preferred embodiment, the parameter characteristic is the bit size of the parameter. If the lowest mode is determined for encoding the speech signal, the remaining modules of the SBRA algorithm module, the middle mode selection module 408 and the high mode refinement module 410 , may be bypassed for the remainder of encoding process. This is because there is only one lowest codec mode, so no further determination of codec modes is required.
[0072] If the speech frame requires a higher codec mode, the determination of the codec mode may be delayed until after LPC calculation but before LTP calculation and may be performed by the middle mode selection module 408 .
[0073] Middle mode selection is when the use of a middle codec mode is determined, which in this example is the 8.85 kbit/s mode. This may be performed by the middle mode selection module 408 , which examines the data output by the LPC calculation module. The middle mode may need to be determined before generation and quantisation of the LTP parameters, such as a LTP filtering flag parameter, a pitch delay parameter and a gain parameter, as the middle codec mode may have different LTP parameter characteristics compared with the higher codec modes. In a preferred embodiment, the parameter characteristic is the bit size of the parameter. If the middle codec mode, in this example the 8.85 kbit/s mode, is determined for encoding the speech frame, the remaining modules of the SBRA algorithm module are bypassed for the remainder of encoding process. This is because there is only one middle codec mode, so no further determination of codec modes is required. If speech frame requires a higher codec mode, the determination of the codec mode may be delayed until after LTP calculation but before excitation calculation and may be performed by the high mode refinement module 410 .
[0074] High mode refinement is when the use of one of the higher codec modes is determined. In this example, the higher codec modes are 12.2, 14.25, 15.85, 18.85, 19.25, 23.05 23.85 kbit/s. The high mode may need to be determined before calculation and quantisation of the excitation signal, because all the higher modes have different excitation signal characteristics, also referred to as the algebraic codebook parameter characteristic. In a preferred embodiment, the algebraic codebook parameter characteristic is the bit size of the algebraic codebook parameter. The final decision as to which of the higher codec modes to use may be based the speech frame characteristics or the speech class.
[0075] FIG. 6 shows a signal flow diagram illustrating the processing that occurs between the SBRA algorithm module and the speech encoder in a preferred embodiment of the invention. The embodiment illustrated in FIG. 6 is a more general embodiment to that illustrated in FIG. 5 .
[0076] In FIG. 6 , speech encoding may be performed by a plurality of speech encoding algorithm groups on each speech frame. There are N speech processing algorithm groups: speech processing algorithm group I, 502 , speech processing algorithm group II, 503 , and speech processing algorithm group N, 504 illustrated in FIG. 6 . It should be appreciated that other speech processing algorithm groups may be present that are not illustrated in FIG. 6 . Speech processing algorithm group I may perform LPC calculations, such as calculating ISP parameters, and may be implemented in the LPC calculation module 407 . Speech processing algorithm group II may perform LTP calculations, such as calculating LTP filtering flag parameters, pitch delay parameters and gain parameters, and may be implemented in the LTP calculation module 409 . Speech processing algorithm group N may perform excitation calculations, such as calculating algebraic codebook parameters, and may be implemented in the fixed code book excitation module 411 .
[0077] Each speech algorithm group may comprise a plurality of speech processing algorithms. Each speech processing algorithm may perform different calculations and/or calculate different speech encoding parameters, which may vary in their characteristics of bit size.
[0078] Speech processing algorithm group I comprises speech processing algorithm I-A, 503 and speech processing algorithm I-B, 504 . Speech processing algorithm group II comprises speech processing algorithm II-A, 507 , speech processing algorithm II-B, 508 , speech processing algorithm II-C, 509 , and speech processing algorithm II-D, 510 . Speech processing algorithm group N comprises speech processing algorithm N-A, 515 , speech processing algorithm N-B, 516 , speech processing algorithm N-C, 517 , speech processing algorithm N-D, 518 , speech processing algorithm N-E, 519 , speech processing algorithm N-F, 520 , speech processing algorithm N-G, 521 , and speech processing algorithm N-H, 522 .
[0079] The signal flow diagram of FIG. 6 also includes a first mode selection branch point 502 , a plurality of second mode selection branch points 505 and 506 , and a plurality of third mode selection branch points 511 , 512 , 513 and 514 .
[0080] The first mode selection branch point 502 is located before speech processing algorithm group I and may correspond to the determining of a codec mode by the low mode selection module 406 . The first mode selection branch point receives a speech frame 501 and determines whether one of the higher codec modes or one of the lower codec modes should be used for encoding the speech frame. If one of the higher codec modes is determined, the speech frame follows path 550 and is encoded by speech processing algorithm I-A 503 . If one of the lower codec modes is determined, the speech frame follows path 551 and is encoded by speech processing algorithm I-B. In the preferred embodiment, the lower and higher codec modes have a different LPC parameter characteristic such as the bit size of the LPC parameter.
[0081] The second mode selection branch points 505 and 506 are located before speech processing algorithm group II and may correspond to the determining of a codec mode by the middle mode selection module 408 . The second mode selection branch points receive speech frames from speech processing algorithm group I and determines more specifically which ones of the higher or lower codec modes should be used for encoding the speech frame. In the preferred embodiment, the determined codec modes have a different LTP parameter characteristic such as the bit size of the LTP filtering flag, the pitch delay or the gain parameter.
[0082] The third mode selection branch points 511 , 512 , 513 and 514 are located before speech processing algorithm group III and may correspond to the determining of a codec mode by the high mode refinement module 410 . The third mode selection branch points receive speech frames from speech processing algorithm group II and determines exactly which codec mode should be used for encoding the speech frame, and completes the encoding of the speech frame accordingly. In the preferred embodiment, the determined codec modes have a different algebraic codebook parameter characteristic such as the bit size of the algebraic codebook parameter.
[0083] In the preferred embodiment of the present invention, the determination on the codec mode to use is delayed as long as possible. During this delay more information can obtained from the speech frame, such as LPC and LTP information, which provides a more accurate basis for codec mode selection than in previously known SBRA systems.
[0084] In a further embodiment of the present invention, the SBRA algorithm exploits the speech encoding parameters determined from the current and previous speech frames for classifying the speech. Therefore, the codec mode selection, which is dependent on speech class, may be dependent on the speech encoding parameters from the current speech frame and the previous speech frames.
[0085] The SBRA algorithm may compare the determined encoded speech parameters, such as the LPC, LTP and excitation parameters, against thresholds. The values to which these thresholds are set may depend on the target bit rate. The thresholds used by the SBRA algorithm for codec mode selection may be stored in a tuning codebook (CB). The tuning CB can be represented as a matrix, TCB, where each row includes a set of tuned thresholds for a given codec mode. For example:
[0000]
TCB
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TCB
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1
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X
1
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⋮
⋮
⋱
⋮
p
TCB
X
n
,
1
…
…
…
p
TCB
X
n
,
m
]
[0000] where the columns of TCB are the set of tuned values for certain threshold. For example, the element p TCB X r ,a from TCB indicates ath tuning parameter, for example the ISP parameter, for the codec mode of X r kbps. An index pointing towards the first row gives the set of parameter thresholds for the highest codec mode X 1 , and the index pointing towards the last row gives the set of parameter thresholds for the lowest codec mode X n .
[0086] The active mode set is the group of codec modes which may be available for encoding. This may be determined by network conditions such as the capacity of the network. The codec modes are sequenced in growing bit rate order, where M 1 set is the codec mode with lowest coding rate. An example of an active mode set is as follows:
[0000] M set =[4.75 kbps 5.90 kbps 7.40 kbps 12.2 kbps]
[0000] Operation mode refers to the highest mode in the active codec set. This mode may be determined by the channel conditions, such as by link adaptation.
[0087] The tuning CB is therefore dependent on the active mode set, and in particular the available codec modes.
[0088] The SBRA algorithm may compare each of the parameters from the encoding of a speech frame and determine which set of parameter thresholds in the tuning CB are met. The codec mode for which all the parameters in the tuning CB have been met is selected as the preferred codec mode. The parameter thresholds are generally set so that at least one of the codec modes can be selected.
[0089] Network constraints such as network capacity and other transmission considerations can mean that the actual bit rate of the selected codec may not be the same as the target bit rate.
[0090] The SBRA algorithm may be either a closed loop system or an open loop system. In an open loop system, the specific thresholds for each parameter in the tuning CB are set when the target bit rate is set or changed. In a closed loop system, the specific thresholds for each parameter may also vary according to the difference between target bit rate and the actual bit rate or the bit rate of the codec selected. Therefore, feedback in a closed loop system may provide for more accurate convergence towards the target bit rate compared to an open loop system.
[0091] In AMR and AMR-WB, VAD is typically used to help in lowering the bit rate during silence periods. However, active speech is coded by a codec mode selected according to network capacity and radio channel conditions. According to another embodiment of the present invention, SBRA algorithm may be implemented as an extension to VAD rather than in a separate module. The complexity of the extension may be kept very low compared to previous SBRA algorithms, as some of the parameters used by the SBRA algorithm in determining codec mode selection are obtained from calculations made by the VAD algorithm. This may result in higher capacity networks and storage applications while maintaining the same speech quality.
[0092] FIG. 7 illustrates a block diagram of another embodiment of the present invention. FIG. 7 illustrates a VAD module 702 , a SBRA algorithm module 705 , a DTX module 716 and a speech encoder 717 .
[0093] The VAD module 702 comprises a filter bank module 703 , which may be used for the computation of parameters such as the sub-band, or frequency band, energy levels in a speech frame, and a background noise estimation module 704 , which may be used for the computation of parameters such as background noise estimates for a speech frame. The VAD module receives a speech frame 701 and determines whether the frame comprises active speech or silence periods. This is done by analysing the energy levels of each sub-band of the speech frame at the filter bank module and analysing the background noise estimate at the background noise estimation module. A VAD flag corresponding to the presence of a silence frame or period is set depending on the result of the analysis. For silence periods, the DTX module is activated and transmission interrupted during the silence period. For active speech, the speech frame may be provided to the SBRA algorithm module via connection 707 . Preferably, parameters from the analysis by the filter bank module and the background noise estimation module are also transmitted to the SBRA algorithm module for use in calculations by the SBRA algorithm module. The SBRA algorithm module may use at least some of these parameters for its calculations without the need to calculate them separately.
[0094] It should be appreciated that whilst the parameters from the VAD algorithm module are illustrated as being provided to the SBRA algorithm module via connection 707 in FIG. 7 , this provision may be done by directly transmitting the parameters between the modules or by storing the parameters in suitably configured medium such as in a memory or a buffer, which can be accessed by both the VAD algorithm module and the SBRA algorithm module.
[0095] The SBRA algorithm module comprises a sub-band level normalisation module 708 , a long term energy calculation module 709 , a frame content analysis module 710 , a low energy threshold scaling module 711 , a mode selection algorithm module 712 , an average bit rate estimation module 713 , a target bit rate tuning module 714 and a tuning CB module 715 .
[0096] Sub-band level normalisation is performed by the sub-band level normalisation module 708 for active speech frames. The table below illustrates the typical band levels of a speech frame and the associated frequency range:
[0000] Band number Frequencies 1 0-250 Hz 2 250-500 Hz 3 500-750 Hz 4 750-1000 Hz 5 1000-1500 Hz 6 1500-2000 Hz 7 2000-2500 Hz 8 2500-3000 Hz 9 3000-4000 Hz
The total energy, totalEnergy j , of all bands in the jth speech frame is given by:
[0000]
totalEnergy
j
=
∑
i
=
1
9
(
vad_filt
_band
i
j
-
bckr_est
i
j
)
[0000] and calculated by the sub-band level normalisation module.
[0097] Normalisation of the energy levels in each sub-band of the speech frame is calculated as follows:
[0000]
NormBand
i
j
=
(
vad_filt
_band
i
j
-
bckr_est
i
j
)
totalEnergy
j
,
[0000] where NormBand i j is the normalised ith band of jth speech frame. The parameters, bckr_est i j and vad_filt_band i j , are the background noise estimate and energy level of ith band in jth speech frame respectively.
[0098] The background noise estimate, bckr_est i j , and the energy levels, vad_filt_band i j , are preferably provided by the background noise estimation module 704 and filter bank module 703 respectively. These parameters may be provided by the background noise estimation module and filter bank module of the VAD algorithm module to the SBRA algorithm module via connection 707 .
[0099] The normalization of the energy levels from the calculated by the sub-band level normalization module 708 may then be used by the frame content analysis module 710 . The frame content analysis module performs frame content analysis for each speech frame, where the frequency content of a speech frame is determined. One of the variables calculated is the average frequency of the speech frame. The average frequency of the speech frame may be calculated based on parameters obtained from the sub-bands energy level calculations from the filter bank module 703 . The parameters from the sub-band energy level calculations, such as the sub-band energy levels, are preferably passed from the filter bank module 703 to the frame content analysis module 710 and therefore do not need to be calculated by the frame content analysis module separately.
[0100] Other parameters calculated by the frame content analysis module include speech stationarity, the maximum pitch difference stored in the LTP pitch lag buffer and the energy level difference between the current and previous speech frames.
[0101] The long term energy calculation module 709 estimates a value for the long term energy of the active speech signal level by analyzing each speech frame together with the parameters from the sub-band level normalization module. The estimated value of the long term energy is used by the low energy threshold scaling module 711 . The low energy threshold scaling module 711 is used for detecting low energy speech sequences for use in mode selection by the mode selection algorithm module.
[0102] The average bit rate estimation module 713 calculates the average bit rate of previous frames, for example, the last 100 frames. The average bit rate is used to tune the target bit rate, which is performed by the target bit rate tuning module 714 . The target bit rate tuning module receives a bit rate target 706 , which may be determined by link adaptation for example, and controls the average bit rate and tuning parameters for the tuning codebook module 715 .
[0103] The mode selection algorithm module 712 determines the codec mode to be selected for speech encoding. The module uses parameters calculated by the other SBRA algorithm modules, such as the tuning codebook module 715 , the low energy threshold scaling module 711 , the long-term energy calculation module 709 and frame content analysis module 710 to select a codec mode. The codec mode selected is passed to the speech encoder 717 , which encodes the speech frame accordingly. LTP information and fixed codebook gain information 721 obtained during speech encoding can be fed back to the frame content analysis module 710 .
[0104] In the preferred embodiment, the SBRA algorithm module, and in particular, the sub-band level normalisation module and the frame content analysis module, can utilise parameters provided by the filter bank module and the background noise estimation modules of the VAD module. As such, these parameters do not need to be calculated separately by the SBRA algorithm module, resulting in an SBRA algorithm module that is simpler to implement compared to previously known ones, where the calculations performed by the VAD algorithm module and the SBRA algorithm module are entirely separate
[0105] The embodiment provides a lower complexity method for determining codec mode than in previous SBRA systems, as at least some of the parameters used for determination are calculated in the VAD module. The computational part of the SBRA algorithm module can therefore kept to a minimum. This may also result in lower storage capacity requirements and require less resource for implementation compared to previous SBRA algorithm modules.
[0106] It should be noted that whilst the preceding discussion and embodiments refer to ‘speech’, a person skilled in the art will appreciate that the embodiments can equally be to other forms of signals such as audio, music or other data, as alternative embodiments and as additional embodiments.
[0107] It is also noted herein that while the above describes exemplifying embodiments of the invention, there are several variations and modifications which may be made to the disclosed solution without departing from the scope of the present invention as defined in the appended claims. | A method and apparatus include a voice activity detection module configured to detect silent frames, and a codec mode selection module configured to determine a codec mode. The voice activity detection module includes a receiver configured to receive a frame, a first determiner configured to determine a first set of parameters from the frame, and a providing unit configured to provide the first set of parameters to the codec mode selection module. The codec mode selection module includes a second determiner configured to determine a second set of parameters in dependence on the first set of parameters, and a selector configured to select a codec mode in dependence on the second set of parameters. | 6 |
BACKGROUND AND SUMMARY OF THE INVENTION
The present invention is directed to architectural joint systems, and particularly to a novel and improved multi-functional cover device, arranged to span the gap between two adjacent, spaced apart architectural structures, such as walls or ceilings, for example.
In the design of architectural structures, where significant expansion and contraction activity may be expected, and/or where the threat of seismic activity is present, it is desirable to design architectural structures in a manner that provides for predetermined spacing between adjacent structural segments. This provides for a degree of freedom of relative motion between the adjacent segments without causing damage to the structure. Where joints of this type are provided, it is conventional to provide cover means, spanning the open space between adjacent structural units, for both aesthetic and functional purposes.
The present invention is directed to a generally simplified form of wall cover system, comprising a novel multi-functional cover plate element, arranged to span over the open space between two adjacent structural units and to be secured to one or both of them by a variety of means.
Simple slidable cover plate elements are, of course, well known in the art, and a variety of designs have been provided to enable mounting of the cover plates in a convenient and economical way. Inasmuch as the optimum mounting of a cover plate element may vary with different types of structures, manufacturers have been required to carry inventories of several types of cover plates, which imposes significant cost factors, not only with respect to the required production tooling, but also in connection with inventorying of parts and the handling thereof, etc.
In accordance with the present invention, a novel and simplified form of cover plate member is designed for multiple utilization, capable of being mounted and employed in a wide variety of ways. This enables the manufacturer and/or contractor to reduce inventory and handling costs, and simplifies installation at the job site. The cover element of the invention is a unitary, multi-functional extrusion of a material such as aluminum, which incorporates features enabling installation in a variety of ways, depending upon the requirements of the job and/or the preferences of the contractor. The cover plate configuration of the invention enables the plate to be secured by exposed or concealed fastening means, to be secured by a centering device, as well as fixed at one side, and to receive a decorative cover or not, as desired. While the individual functions are, in a general way, individually known, the construction of a single, multi-functional cover element incorporating all of these features, results in significant and unobvious advantages, and enables economies to be realized by both the contractor and the ultimate user.
For a more complete understanding of the above and other features and advantages of the invention, reference should be made to the following detailed description of preferred embodiments of the invention and to the accompanying drawings.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a fragmentary cross sectional view of an architectural joint provided with a cover system according to the present invention, which is fixed at one side and slidable at the opposite side.
FIG. 2 is a cross sectional view, similar to FIG. 1, but showing the wall cover system employed with a decorative cover.
FIG. 3 is a cross sectional view of a modified form of the invention, in which the wall cover system is mounted in the joint in a manner to maintain the wall cover plate substantially centered with respect to the respective adjacent architectural units as they move toward and away from each other.
FIG. 4 is a cross sectional view similar to FIG. 1, illustrating the multi-functional wall cover unit as installed by means of a plurality of concealed clips.
DESCRIPTION OF PREFERRED EMBODIMENTS
Referring now to the drawing, and initially to FIG. 1, the reference numerals 10, 11 designate generally a pair of spaced apart architectural units defining a space 13 between them. In the illustration, the architectural units are interior wall or ceiling segments comprising sheet rock panels 14 and metallic studs 15, 16. A cover plate 17, in the form of a continuous extrusion of aluminum or other suitable material, having a uniform cross section throughout, spans over the space 13 between the architectural units. The cover 17 is arranged to contact the outer surfaces 18, 19 of the wall panels 14, and to be slidable with respect to at least one of them.
Adjacent the opposite side edge of the cover 17 there are rearwardly projecting integral channels 20, 21 arranged to receive continuous resilient contact strips 22, 23, providing for a resilient, noise-free contact with the wall panel surfaces 18, 19. The main panel 24 of the cover is preferably generally flat but can be provided with decorative surface features if desired.
The opposite side edge extremities 25, 26 of the cover plate 17 desirably are of generally semi-cylindrical contour oriented to be outwardly convex. The rearward extremities of the semi-cylindrical edges terminate generally adjacent to and approximately at the level of the rearwardly projecting channels 20, 21. In the illustrated arrangement, the resilient contact strips 22, 23 include portions which extend laterally outward to underlie the extremities of the semi-cylindrical edges 25, 26 so that, viewed from the edge, there does not appear to be any significant gap between the edges 25, 26 and the surfaces 18, 19 of the underlying wall board panels.
Pursuant the invention, the cover plate 17 is provided with a variety of combinations of elements for mounting the cover plate usefully with respect to the wall panels 18, 19 and the space 13 therebetween. In the arrangement of FIG. 1, the cover plate is mounted by means of a plurality of screws 27, received in appropriately spaced holes 28 provided in the cover plate. To this end, the cover plate of the invention is provided with an anchoring base section 29, in the form of a strip-like section of the cover plate closely adjacent to and extending longitudinally along one of the rearwardly projecting channels 21. In most cases, the wall thickness of the main panel 24 of the cover plate is relatively thin, and marginally adequate for the retention of the screws 27. Accordingly, the strip-like anchoring base portion 29 desirably is of somewhat greater thickness than the balance of the main cover plate panel 24. While it would of course be possible to make the entire cover plate 17 of sufficient wall thickness to support the mounting screws 27, this would be generally an over design of the cover plate and a wasteful and costly use of materials. Accordingly, the anchor base 29 is most advantageously in the form of a relatively narrow, elongated strip, slightly wider than the head portion 30 of a typical countersunk mounting screw.
To advantage, the cover plate 17 is provided with a support leg 31, projecting rearwardly from the main panel 24 and positioned to lie on the opposite side of the mounting screws 27 from the adjacent contact strip 23. In this manner, the cover plate is supported closely adjacent to, and on opposite sides of, the mounting screws. With this configuration, distortion of the cover plate 24, resulting from overtightening of the screws 27 during the installation process, is minimized or avoided. Significantly, the supporting leg 31 forms part of an alternative mounting feature as will be described hereinafter.
In the mounting arrangement illustrated in FIG. 1, the cover plate 17 is rigidly secured to one of the structural units 11, and relative motion between the structural units 10, 11 results in relative movement between the unit 10 and the cover plate. The width of the cover plate is thus selected so that the overlap at the relatively movable side is sufficient to accommodate the expected separating movements of the structural units 10, 11.
In FIG. 2, there is shown a form of the invention in which the cover plate 17 is completely covered by a decorative snap-on shell 35, advantageously a continuous extrusion of uniform cross section, formed of a plastic material, such as rigid vinyl. At its opposite side edges 36, 37, the plastic shell is contoured to be of generally semi-cylindrical configuration, with the interior contours of the plastic shell conforming generally to the external contours of the edges 25, 26 of the cover plate. There is sufficient resilience in the rigid vinyl or other plastic material constituting the decorative shell 35, to enable the shell to be forcibly applied over the metal cover plate 17, after mounting thereof on the wall panels 14 of the respective architectural units 10, 11. In a typical installation procedure, one of the semi-cylindrical edges 36 or 37 is hooked over a corresponding edge 25, 26 of the cover plate 17 and then the opposite side edge is forced over its corresponding cover edge until it finally snaps in place in the final position shown in FIG. 2. The use of the cover shell 35 is particularly advantageous when using the mounting arrangement of FIG. 1, for example, because it completely conceals the otherwise visible screw heads 30. However, the plastic shell cover may also be advantageously used in any of the versions of the invention, as it provides for wide flexibility of colors and surface decorations.
The arrangement of the invention shown in FIG. 3 incorporates a mounting system accommodating relative motion between the cover plate 17 and the wall panels of each of the structural units 10, 11, in a manner to maintain the cover 17 substantially centered with respect to the open space 13 between the relatively movable architectural units. For this purposes, the multi-functional wall cover element of the invention includes a continuous, rearwardly opening channel 40, formed by spaced apart, opposed generally L-shaped flanges 41, 42 arranged symmetrically with respect to the center line of the cover plate. The L-shaped flanges form opposed, spaced apart, laterally opening recesses 43, 44 arranged for the longitudinally slidable reception of flange portions 45 of a spring clip 46. At its inner end, the spring clip 46 has a normally generally W-shaped configuration, including outwardly and forwardly directed spring legs 47, 48. The spring legs, in their normal orientation have a spacing between their respective outer extremities 49, 50 which is at least somewhat greater than the maximum expected width of the space 13 between the respective architectural units 10, 11.
For installation of the cover plate in the manner illustrated in FIG. 3, a plurality of spring clips 46 are slidably engaged in the channel 40, spaced apart along the length of the cover plate 17 at suitable intervals. Desirably, there is sufficient friction between the mounting portions 45 of the spring clips and the channel 40, that the spring clips will remain substantially in their preset positions during the installation process.
The cover plate, with the spring clips 46 properly spaced, is positioned over the open space 13 and the clips 46 are forced into the space, squeezing inwardly on the spring legs 47, 48. The cover is pushed inwardly until the contact strips 22, 23 are snugly engaged with the outer surfaces 18, 19 of the wall panels 14. Thereafter, the spring clips 46 are self-locking in position, as the end extremities 49, 50 thereof tend to dig into the outer surfaces of the opposed studs 15, 16.
As the structure units 10, 11 move toward and away from each other in the course of expanding and contracting, or for other reasons, the spring legs 47, 48 simply are compressed toward each other or released outwardly, in all cases maintaining contact with the studs 56, at least until the designed limits of expansion have been exceeded. During the expanding and contracting motions, the cover plate 17 will tend to retain itself in more or less centered relation to the space 13 between the structural units, as will be appreciated.
In the form of the invention illustrated in FIG. 4, the cover plate 17 is fixed to one of the wall panels and is slidable with respect to the other, in the manner of the installations of FIGS. 1 and 2. In the FIG. 4 installation, however, concealed clips are employed to effect the mounting. In this respect, there is provided adjacent the anchoring base 29 a rearwardly opening continuous U-shaped channel 60, which is defined on the inside by the supporting leg 31, and on the outside by a downwardly projecting flange 62, which is slightly shorter than the supporting leg 31. The internal walls of the U-shaped channel can be serrated if desired.
For mounting the cover plate in the manner of FIG. 4, a plurality of L-shaped clips 63 are secured to the face of the structural unit 11, adjacent to the space 13, by means of screws 64. The L-shaped clips 63 are aligned so that the vertical legs 65 thereof lie substantially in a common plane, at right angles to the surface 19 of the wall board panel 14. A plurality of the L-shaped clips 63 are mounted in suitably spaced relation along the side of the space 13. Thereafter, the cover 17 is pressed over the vertical legs 65 of the clips, until the latter are fully received within the rearwardly opening recesses 60. The L-shaped clips 63 and the recess 60 suitably interact to frictionally retain the cover plate 17 in position, with the contact strips 22, 23 bearing against the surfaces 18, 19 of the wall panels. To this end, the vertical legs 65 of the L-shaped clips may be provided with serrations or barbs, or other means to interengage with the walls of the recess 60. Typically, when the clips 63 are fully received in the U-shaped recess 60, the support leg 31 is in contact with the outer surface 19 of the wall board panel, as reflected in FIG. 4.
If desired, the L-shaped clips may be designed so that the vertical legs thereof comprise a plurality of sections adapted to grip opposite surfaces of a single element projecting rearwardly from the cover.
The multi-functional cover plate of the invention enables the manufacturer and/or contractor to inventory a single part, which can be installed in a wide variety of ways, depending upon the nature of the structure and/or the desires of the architect. Heretofore, the illustrated variety of mounting arrangements has only been provided by utilizing cover plates individually designed for the purpose. With the device of the present invention, surprising and unexpected advantages are realized by providing a cover plate design which is multi-functional and incorporates in a single, inexpensive extrusion all of the facilities necessary to accommodate various mounting arrangements, as well as the optional use of a snap-on plastic cover.
It should be understood, of course, that the specific forms of the invention herein illustrated and described are intended to be representative only, as certain changes may be made therein without departing from the clear teachings of the disclosure. Accordingly, reference should be made to the following appended claims in determining the full scope of the invention. | The present invention is directed to architectural joint systems, and particularly to an improved multi-functional cover device, arranged to span the gap between two adjacent, spaced apart architectural structures, such as walls or ceilings. The cover system comprisies a multi-functional cover plate element can be secured by a variety of means. | 4 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to traffic controls and more particularly pertains to a new lighted traffic channelization device for diverting traffic around hazards or construction areas in the dark.
2. Description of the Prior Art
The use of traffic controls is known in the prior art. More specifically, traffic controls heretofore devised and utilized are known to consist basically of familiar, expected and obvious structural configurations, notwithstanding the myriad of designs encompassed by the crowded prior art which have been developed for the fulfillment of countless objectives and requirements.
Known prior art includes U.S. Pat. No. 5,613,798; U.S. Pat. No. 5,036,791; U.S. Pat. No. 4,973,190; U.S. Pat. No. 5,201,599; U.S. Pat. No. Des. 320,172; and U.S. Pat. No. Des. 277,739.
While these devices fulfill their respective, particular objectives and requirements, the aforementioned patents do not disclose a new lighted traffic channelization device. The inventive device includes a conically shaped barrel assembly having a base unit and a selectively couplable top section. The top section incorporates a battery-operated handle member which flashes sequentially when automatically activated by a photoelectric device when it becomes dark.
In these respects, the lighted traffic channelization device according to the present invention substantially departs from the conventional concepts and designs of the prior art, and in so doing provides an apparatus primarily developed for the purpose of diverting traffic around hazards or construction areas in the dark.
SUMMARY OF THE INVENTION
In view of the foregoing disadvantages inherent in the known types of traffic controls now present in the prior art, the present invention provides a new lighted traffic channelization device construction wherein the same can be utilized for diverting traffic around hazards or construction areas in the dark.
The general purpose of the present invention, which will be described subsequently in greater detail, is to provide a new lighted traffic channelization device apparatus and method which has many of the advantages of the traffic controls mentioned heretofore and many novel features that result in a new lighted traffic channelization device which is not anticipated, rendered obvious, suggested, or even implied by any of the prior art traffic controls, either alone or in any combination thereof.
To attain this, the present invention generally comprises a conically shaped barrel assembly having a base unit and a selectively couplable top section. The top section incorporates a battery-operated handle member which flashes sequentially when automatically activated by a photoelectric device when it becomes dark.
There has thus been outlined, rather broadly, the more important features of the invention in order that the detailed description thereof that follows may be better understood, and in order that the present contribution to the art may be better appreciated. There are additional features of the invention that will be described hereinafter and which will form the subject matter of the claims appended hereto.
In this respect, before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting.
As such, those skilled in the art will appreciate that the conception, upon which this disclosure is based, may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.
Further, the purpose of the foregoing abstract is to enable the U.S. Patent and Trademark Office and the public generally, and especially the scientists, engineers and practitioners in the art who are not familiar with patent or legal terms or phraseology, to determine quickly from a cursory inspection the nature and essence of the technical disclosure of the application. The abstract is neither intended to define the invention of the application, which is measured by the claims, nor is it intended to be limiting as to the scope of the invention in any way.
It is therefore an object of the present invention to provide a new lighted traffic channelization device apparatus and method which has many of the advantages of the traffic controls mentioned heretofore and many novel features that result in a new lighted traffic channelization device which is not anticipated, rendered obvious, suggested, or even implied by any of the prior art traffic controls, either alone or in any combination thereof.
It is another object of the present invention to provide a new lighted traffic channelization device which may be easily and efficiently manufactured and marketed.
It is a further object of the present invention to provide a new lighted traffic channelization device which is of a durable and reliable construction.
An even further object of the present invention is to provide a new lighted traffic channelization device which is susceptible of a low cost of manufacture with regard to both materials and labor, and which accordingly is then susceptible of low prices of sale to the consuming public, thereby making such lighted traffic channelization device economically available to the buying public.
Still yet another object of the present invention is to provide a new lighted traffic channelization device which provides in the apparatuses and methods of the prior art some of the advantages thereof, while simultaneously overcoming some of the disadvantages normally associated therewith.
Still another object of the present invention is to provide a new lighted traffic channelization device for diverting traffic around hazards or construction areas in the dark.
Yet another object of the present invention is to provide a new lighted traffic channelization device which includes a conically shaped barrel assembly having a base unit and a selectively couplable top section. The top section incorporates a battery-operated handle member which flashes sequentially when automatically activated by a photoelectric device when it becomes dark.
Still yet another object of the present invention is to provide a new lighted traffic channelization device that provides a self-contained, automatic lighted indicator of the presence of the barrel during hours of darkness.
Even still another object of the present invention is to provide a new lighted traffic channelization device that is easier to handle and take up less storage area.
These together with other objects of the invention, along with the various features of novelty which characterize the invention, are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and the specific objects attained by its uses, reference should be made to the accompanying drawings and descriptive matter in-which there are illustrated preferred embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood and objects other than those set forth above will become apparent when consideration is given to the following detailed description thereof. Such description makes reference to the annexed drawings wherein:
FIG. 1 is a perspective view of a new lighted traffic channelization device according to the present invention.
FIG. 2 is a side view of the top section of the present invention.
FIG. 3 is a bottom view of the top section of the present invention.
FIG. 4 is a perspective view depicting the stackability of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference now to the drawings, and in particular to FIGS. 1 through 4 thereof, a new lighted traffic channelization device embodying the principles and concepts of the present invention and generally designated by the reference numeral 10 will be described.
As best illustrated in FIGS. 1 through 4, the lighted traffic channelization device 10 generally comprises a barrel assembly 12 . The barrel assembly 12 includes a base unit 14 . The base unit 14 has a substantially conical shaped cross-section such that the base unit 14 is designed for resting on a support surface.
The barrel assembly 12 includes a top section 16 . A coupling portion 18 of the top section 16 is threadably couplable to an upper end of the base unit 14 thereby forming the barrel assembly 12 .
The top section 16 includes a handle member 20 . The handle member 20 is positioned on an upper surface 22 of the top section 16 . The handle member 20 is designed for gripping onto by a hand of a user, thereby allowing the user to carry the barrel assembly 12 when the top section 16 and the base unit 14 are coupled.
The handle member 20 of the top section 16 includes a light source 24 . The light source 24 is located in a grip portion 26 of the handle member 20 . The light source 24 is designed for sequentially emitting light thereby allowing drivers to see the barrel assembly 12 in the dark.
The base unit 14 of the barrel assembly 12 has a flange portion 28 . The flange portion 28 is positioned proximate a lower end 30 of the base unit 14 . The flange portion 28 is designed for maintaining the base unit 14 in an upright position.
The barrel assembly 12 comprises a durable lightweight material 32 such that the barrel assembly 12 is designed for being utilized in a rugged environment.
The grip portion 26 of the handle member 20 comprises a semi-transparent material 34 such that light from the light source 24 is emitted outwardly.
The grip portion 26 is designed to conform to the hand of a user thereby allowing the user to grasp onto the barrel assembly 12 .
The top section 16 of the barrel assembly 12 includes a battery 36 . The battery 36 is positioned inside the top section 16 . The battery 36 is designed for providing power to the light source 24 .
The top section 16 of the barrel assembly 12 includes a photoelectric device 38 . The photoelectric device 38 is located on a side surface 40 of the top section 16 . The photoelectric device 38 is operationally coupled to the battery 36 and the light source 24 such that the photoelectric device 38 is designed for switching on the light source 24 when a lack of sunlight is present, thereby allowing the light source 24 to automatically emit light when it is dark out.
The top section 16 of the barrel assembly 12 includes a cover member 42 . The cover member 42 is located on a bottom surface 44 of the top section 16 . The cover member 42 has a plurality of fastening members 46 . The fastening members 46 are designed for selectively coupling the cover member 42 to the bottom surface 44 of the top section 16 . The cover member 42 is designed for accessing the battery 36 , the photoelectric device 38 , and the light source 24 .
The base unit 14 of the barrel assembly 12 is substantially hollow such that the barrel assemblies are stackable.
As to a further discussion of the manner of usage and operation of the present invention, the same should be apparent from the above description. Accordingly, no further discussion relating to the manner of usage and operation will be provided.
With respect to the above description then, it is to be realized that the optimum dimensional relationships for the parts of the invention, to include variations in size, materials, shape, form, function and manner of operation, assembly and use, are deemed readily apparent and obvious to one skilled in the art, and all equivalent relationships to those illustrated in the drawings and described in the specification are intended to be encompassed by the present invention.
Therefore, the foregoing is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention. | A lighted traffic channelization device for diverting traffic around hazards or construction areas in the dark. The lighted traffic channelization device includes a conically shaped barrel assembly having a base unit and a selectively couplable top section. The top section incorporates a battery-operated handle member which flashes sequentially when automatically activated by a photoelectric device when it becomes dark. | 4 |
BACKGROUND OF THE INVENTION
This invention relates to cards with sliding flats in which fibrous material in thin layer form is worked by a series of surfaces provided with a plurality of points of various shape, inclination and rigidity and driven to move relative to each other, in which the fibrous material is opened into single fibre form, the small trash particles being eliminated together with waste and tangles, the fibres undergoing mutual mixing to form a sliver of untwisted fibres to be fed to the subsequent working stages.
DESCRIPTION OF RELATED ART
To highlight the technical problems involved in carding and confronted by the present invention, the flat carding process is described briefly with reference to the carding machine of FIG. 1. The raw material 1 consisting of staple fibres collected into the form of a web of approximately rectangular cross-section is fed to the machine by a feed roller 2 which presses and controls it against the board 3 to feed a strip 4 to the opening cylinder 5. The opening cylinder 5 is provided with clothing, i.e. points inclined opposite the direction of opening cylinder rotation, and is driven at a considerable rotational speed. The fibre strip 4 is hence roughly combed and distributed over the opening cylinder 5 into a layer thinner than the original layer 1. During its anticlockwise rotation the fibre layer encounters clothed segments and blades for removing impurities, after which the fibres pass to the subsequent carding drum 6. The drum 6 is driven at a rotational speed less than the opening cylinder 5, but as it has a much larger diameter its peripheral speed is higher. The points on the drum 6 are also inclined in the direction of rotation, to remove the fibres from the surface of the opening cylinder 5 along the closest generating lines between the opening cylinder 5 and the carding drum 6. The moving flats 7 are located above the top of the drum 6. The moving flats 7 are in the form of bars having a length corresponding to the generating line of the carding drum 6 and a few centimeters in width. That part thereof which faces the drum 6 is provided with clothing in the form of points pointing in the direction of movement. Generally the moving flats 7 move slowly in a direction of rotation which is the same as or opposite to the that of the drum 6. The two clothings cooperate with typical carding action to provide fibre extension, cleaning, retention and depth control within the point clothing. It should however be noted that the peripheral drum speed is generally within the range of 15-40 meters per second, whereas the flat speed is of the order of a few millimeters per second.
The flats 7 circulate about the drum periphery conveyed by a drive member, for example a pair of chains 8 circulating about a series of drive and guide sprockets 9. Along the carding path between the drum 6 and flats 7, the flats 7 are guided by guides 10 which are preset with a precision of the order of a tenth and even down to a hundredth of a millimeter, to establish the distances between the drum clothing and the flat clothing, which are essential for the good outcome of the operation. The guides 10 are positioned at the edge of the flat faces of the drum 6, and on them there slide the end parts, without points, of the flats 7. The extended and cleaned fibres become arranged into a thin layer on the carding drum 6.
They are then detached by a discharge cylinder 11, also provided with points inclined in the direction of rotation, to enable the fibres carded by the drum 6 to be withdrawn and then discharged from the cylinder 11 by detachment cylinders not shown in the figure.
The present invention relates in particular to an improved sliding flat for said flat cards and a system for guiding and driving it. In the traditional art the flats are generally driven by drive chains 8 to which the flats are fixed by means of bushes, brackets and various supports, either on the chain joints or plates, by screw elements, by snap rings, form fits and so on. European patent application 92/201945 in the name of the present applicant describes and claims various form fits between flats and chains without fixed means for retention in the direction perpendicular to the chain movement, with high accuracy in the direction of the guides 10 and with the facility for removal even with the machine in motion.
In the traditional art the bodies of the flats are generally constructed of ferrous material by casting, typically of cast iron, to which the point clothing for the carding is then applied.
This type of construction satisfies the requirements of reliability, reproducibility, rigidity and life, but at the cost of an overall very heavy structure which results in considerable construction, installation and maintenance costs of the overall machine.
For these reasons the current tendency of the art is to pursue a lighter and more economical construction, for example by using card flat bodies produced from aluminium or light alloy sections, on which the card clothing is then fixed. These flats, formed from hollow sections of suitable moment of inertia, satisfy the need for good flexural and torsional rigidity, and are lighter and overall less costly even though a more valuable material is used. These light flats allow, inter alia, the general architecture of the machine to be modified, and enable toothed belt drives to be used instead of traditional metal chains.
European patent application EP-A-361 219 of Truetzschler GmbH describes a flat card system of this type. European patent application EP-A-567 747, again of Truetzschler GmbH, describes the insertion of stronger cylindrical pins into the external parts of the flats so that these pins would rest on the guides 10 instead of the ends of the light alloy section, which would wear more rapidly. These pins can be constructed of more wear-resistant materials and can be replaced during periodic machine maintenance at low cost.
European patent application EP-A-627 507 of Maschinenfabrik Rieter AG describes a flat card system of this type with coupling between the flat and the toothed drive belt by means of the actual pins which slide on the guides 10.
The technical arrangements of the cited prior patents have the drawback that the coupling between the card flat and the toothed drive belt is such as to angularly constrain the flat to the belt, so endangering the accuracy with which the flat can follow the guides 10 directionally, given that the belt has a certain intrinsic rigidity.
SUMMARY OF THE INVENTION
An object of the invention is to provide an improved lightweight flat for said flat cards, and a system for guiding and driving it which uses a toothed belt drive but without the stated drawbacks of this type of drive when used in the aforesaid systems. A further object of the present invention is to provide a coupling system between the flat and belt which enables said elements to be easily released from each other for maintenance and for removal during maintenance.
According to the present invention, coupling between the flat and toothed belt is provided only in the direction of movement of the flats, while leaving said elements not coupled together in the direction perpendicular to the movement of the flats, by means of a cylindrical form fit between the flats and chain using recesses and projections of circular cross-section, without fixed means for retaining them in position, and which enables the flat to freely position itself in the direction of the guide 10 without angular constraints caused by the cylindrical coupling with the toothed belts positioned at its ends.
With the above and other objects in view that will hereinafter appear, the nature of the invention will be more clearly understood by reference to the following detailed description, the appended claims and the several views illustrated in the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a highly schematic side elevational view, and illustrates a conventional carding machine including an opening cylinder, a carding drum, a discharge cylinder and a plurality of flats in opposition to an upper portion of the carding drum.
FIG. 2A is a fragmentary side elevational view of a portion of a carding machine of a first embodiment of the invention, and illustrates a toothed belt having alternating teeth and valleys with the valleys having cylindrical cavities receiving cylindrical pins axially projecting from associated flats.
FIG. 2B is fragmentary perspective view of the first embodiment of the invention, and more clearly illustrates details of the coupling pins and cavities and additional pairs of guide pins carried by the flats.
FIG. 2C is a fragmentary side elevational view of an upper portion of the carding machine of the first embodiment of the invention, and illustrates the manner in which the flats are guided during travel along upper and lower drive belt flights.
FIG. 2D is a diagrammatically side elevational view of one of the flats and drive belts, and illustrates details thereof.
FIG. 3A is fragmentary side elevational view of another embodiment of the invention, and illustrates cylindrical coupling cavities in teeth of the drive belt coupling cylindrical pins of flats thereto.
FIG. 3B is a fragmentary perspective view of the embodiment of the invention illustrated in FIG. 3A, and illustrates the details thereof including pairs of additional guide pins carried by each of the flats.
FIG. 3C is a fragmentary side elevational view of an upper portion of the carding machine, and illustrates the manner in which the flats are guided during travel along upper and lower flights thereof.
FIG. 3D is a fragmentary perspective view of another embodiment of the invention, and illustrates an anti-friction bearing carried by a cylindrical pin projecting from each of the flats.
FIG. 4A is a fragmentary side elevational view of another embodiment of the invention, and illustrates cylindrical pins carried by flats coupled to cylindrical coupling cavities in an associated drive belt which open through lower faces of the drive belt.
FIG. 4B is a fragmentary perspective view of the carding machine of FIG. 4A, and illustrates details thereof including additional pairs of guide pins carried by each flat.
FIG. 4C is a fragmentary side elevational view of an upper portion of the carding machine, and illustrates the flats being guided during movement along upper and lower flights of the drive belts.
FIG. 4D is a fragmentary perspective view of a modification of the drive belt of FIGS. 4A through 4C, and illustrates downwardly opening channels formed in the drive belts for reducing the weight thereof.
FIG. 5A is a fragmentary perspective view, and illustrates another embodiment of the invention in which the coupling cavities are located between upper and lower faces of the drive belt and ends of the coupling pins project therethrough and carry anti-friction bearings.
FIG. 5B is a side elevational view of the embodiment of the invention illustrated in FIG. 5A, and illustrates details thereof.
FIG. 5C is a fragmentary cross-sectional view taken through the carding machine, and illustrates axial opposite ends of the coupling pins supported upon guide members through the associated anti-friction bearings.
FIG. 5D is a fragmentary cross-sectional view similar to FIG. 5C, and illustrates the pairs of guide pins supported by the lower guides associated with the carding drum.
FIG. 6A is a fragmentary perspective view of another embodiment of the invention, and illustrates coupling pins of "pear-shaped" configuration which project beyond upper faces of an associated drive belt.
FIG. 6B is a fragmentary side elevational view of the embodiment of the invention illustrated in FIG. 6A, and illustrates details thereof.
FIG. 6C is a fragmentary side cross-sectional view of the carding machine of FIGS. 6A and 6B, and illustrates the projecting portions guidingly supported upon lateral guiding members.
FIG. 6D is a fragmentary transverse cross-sectional view similar to FIG. 6C, and illustrates the flats being guided upon guides associated with the opening cylinder.
FIG. 7A is a fragmentary perspective view of another embodiment of the invention, and illustrates relative large coupling pins having cylindrical portions projecting beyond an upper face of an associated drive belt.
FIG. 7B is a fragmentary perspective view of the embodiment of the invention illustrated in FIG. 7A, and illustrates details thereof.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The flat 7 of FIGS. 2A through 2C is preferably of inverted T cross-section to provide sufficient rigidity against flexural stress between the two guide supports 10, which are spaced apart transversely by a distance D 10 (FIG. 5D) of the order of one meter. The shank 20 of the T is made hollow to achieve a high flexural moment of inertia. The body of the flat 7 is obtained from a light alloy section of indefinite length, which is cut to size to a length less than the distance between the guides 10. A lower face 21 of each flat 7 is not involved with the guides 10 and carries the card clothing 22 (FIG. 2B) indicated roughly as a series of points. The toothed belt 23 has a flat lower face 23a and an undulating upper face 23b. Generally each toothed belt 23 is constructed of material of good flexibility, such as elastomeric materials possibly reinforced longitudinally with textile fibre threads and/or metal wires.
On the worked face 23b of each toothed belt 23 there is provided a series of projecting teeth 24 intended to engage the sprockets 9A, 9B and 9C, and spaced apart by a series of lower longer portions 25, in which there is provided an upwardly open cylindrical cavity 26 of circular cross-section for housing a horizontal pin or element 28 by which the toothed belts 23 are coupled to the flats 7. On the terminal faces at the two ends of the body of the flats 7, and in particular on the part forming the "cross-member of the T", there are fixed in a position closer to the face 21 two pins 27 of wear-resistant material, for example alloy steel, which are positioned horizontally and intended to slide on the card guides 10 to support the working flats 7 facing the drum 6.
Again on the terminal faces of the body of the flats 7, but in a position relatively further from the lower face 21, there is fixed a horizontal pin 28 for insertion into the cylindrical cavity 26. The pin 28 is of cylindrical shape and has a size corresponding to the size of said cavity 26, not only to enable the flat 7 to be driven along its working path but also to enable it to undergo adaptive rotary movements via the pin 28 within the cavity 26, to enable the flat to guide accurately along to the profile of the guides 10.
To allow freedom of said rotational movements in adapting to the path determined by the guides 10, in a preferred embodiment of the invention the support pins 27 are mounted at a substantial distance from the bottom face 23a of the toothed belt 23.
In other words, between the flat 7 and the toothed belt 23 there is provided a cylindrical form fit, without fixed retention means, with the toothed belts positioned at its ends by means of cavities 26 and pins 28 of circular cross-section having their axes transverse to the toothed belt, by which the flat 7 is free to adapt itself angularly by rotating about the coupling axis in the direction of the guide 10 without angular constraints provided by the cylindrical fit.
The pins 27 and 28 can be fixed to the body of each flat 7 in known manner, for example by a forced fit or by a screwed connection.
The embodiment shown in FIGS. 3A, B, C shows a modification to the belt/flat coupling of FIGS. 2. In it, the worked face 23b of the belt 23 is provided with a series of projecting teeth 24' extending further in the longitudinal direction than the depressed portions 25'. Within the teeth 24' there is provided an upwardly open cylindrical cavity 26' intended to house the pin 28'. It can be seen that this embodiment requires a lesser belt thickness than the embodiment of FIG. 2. It also has further advantages which are described hereinafter.
FIG. 3D shows a preferred embodiment of the invention, applicable advantageously to the circular coupling pins of the other described embodiments, in which that part of the pin 28 projecting from the flat 7 is provided with an antifriction rolling bush 29, interposed between the pin 28 and its cavity 26, which reduces friction during mutual rotation.
Along the path guided by the guides 10, for which on the other side of the drum there is another corresponding guide 10 parallel to it, the series of flats 7 are driven by the toothed belts 23 which follow the path defined by the sprockets 9, of which at least one is motorized and at least one is provided with belt tensioning members. As in the case of the guides 10, the sprockets are also provided in pairs, one for each side of the drum 6.
With the coupling systems shown in the embodiments of FIGS. 2 and 3 when the flats separate from the guides 10, the toothed belts 23 retain the flats 7 during their engagement with the sprockets 9 until they have overturned with the clothing 22 on top. After this overturning each flat 7 is supported on the belt 23.
In FIGS. 4A,4B,4C and 4D a toothed belt 33 has its lower face 33a worked to engage the pins 28 and its upper face 33B toothed to engage the sprockets 9 by means of its teeth.
In the lower face 33a there is provided a series of downwardly open cylindrical cavities 34 intended to house the coupling element 28 for the flats 7. In the embodiment of FIG. 4D, the toothed belt 33 is made more flexible and lighter by a series of weight reducing cavities 35, which alternate with the coupling cavities 34.
It should be noted that in the aforedescribed embodiments the cavities 26, 26', 34 are formed with an open cylindrical section, resulting in easier connection between the toothed belt 23 or 33 and the flat 7. It is also possible to form the device of the present invention with the cavities 26, 26', 34 of closed cylindrical section, as shown in particular in FIG. 2D, resulting in a connection with a greater guarantee of retention between the flat and the toothed belt, even if the belts are stressed to the extent of undergoing considerable deformation by elongation.
With the coupling system shown in the embodiments of FIGS. 4, when the flats separate from the guides 10 the toothed belts 33 do not retain the flats during their engagement with the sprockets 9, and consequently supplementary guides 36, of L cross-section and extending as a semicircle, are required to compel the series of flats 7 passing about the sprockets 9A, 9B on the belt 33 not to separate from them until they have overturned with the clothing 22 on top. This difference has however an advantageous side deriving from the fact that along their inoperative upper path from sprocket 9B to sprocket 9A the flats 7 always simply rest on the pair of belts 33. In this respect it must be noted that in carding, the material is such as to require the cylinders and the flats to be subjected to frequent cleaning and to regeneration of the clothing.
In consideration of this and of the large number of flats installed on the machine, of the order of a hundred, it is advantageous to be able to remove and replace a flat by simply lifting it from its site on the pair of belts along its upper path. In devices of the known art, the flats are generally removed and replaced with greater complication. In the embodiment of FIG. 4 each flat 7 is withdrawn without having to remove restrictions. If there are no particular safety regulations the flats 7 can even be removed when in movement, given their low peripheral speed and their instant removability.
Along the working lower path the belts 23, 33 are guided by the flats 7, which in their turn rest continuously on the guides 10. Along the inactive upper path the flats 7 rest on the toothed belts 23, 33, which are considerably stressed by the weight of the flats 7 and may not be able to by themselves support all the flats without dangerous elongation. For this reason, according to a preferred embodiment of the invention, the upper parts joining the sprockets 9A, 9C and 9B are provided with support guides 40 on which the inverted inoperative flats 7 are slidingly supported.
A further technical problem relating to the upper path of the guides 40 derives from the fact that the relative position between the belts 23, 33 and flats 7 is in this case inverted. The flats 7 rest on the belts 23, 33 which could slide on the guides 40, with considerable friction and wear.
According to a preferred embodiment of the present invention, the coupling pins 28, 28' between the belt and flat are made to project from their cavity 26, 26', 34 in the toothed belt 23, 33 such that they rest--with the flats inverted--on the return guides 40 in place of the projecting teeth 24, 24' of the toothed belt This improvement is illustrated with greater detail in the embodiments of FIGS. 5A through 5D and 6A through 6D, by way of non-limiting example. The embodiment of FIGS. 5A through 5D uses the type of coupling shown in FIGS. 3 in which however the coupling pin 41 between the belt 23 and flat 7 is constructed with a length projecting from the end of the flat 7 which is substantially in excess of the width of its toothed belt 23 and consequently projects from it by a portion 42.
As already described, this projecting portion 42 can advantageously have applied to it a further separate antifriction rolling bush 43, which reduces contact friction in its resting on the guide 40.
In FIG. 5C upper pair of support guides 40 which have to support the weight of the flats 7 along their inoperative path are located at a transverse distance apart D 40 which is greater than the transverse overall dimension of the pair of belts 23, which corresponds substantially to the distance D 10 (FIG. 5D) between the guides 10 plus the thickness of the guides themselves, so that the profile of the teeth 24 of the pair of belts 23 remains within guides 40 and does not come into contact with them. The guides 40 are positioned a distance apart D 40 corresponding to that of the two portions 42 so that it is not the toothed belt which rests on the guides 40 but instead the portion 42, preferably provided with an antifriction bush 43, which slides on the guides or guide members 40 along the inoperative path of the flats 7.
The flats 7, which are supported along the path of the guides 10 by the pins 27, are hence supported along the return path of the guides 40 by the pins 42, with reduced friction and wear. In the embodiment shown in FIGS. 5A through 5D, the cavities/are formed with a closed circular cross-section.
In the embodiment of FIGS. 6A through 6D the type of coupling illustrated in FIGS. 3 is again used, but with the coupling pin 46 between the belt 23 and flat 7 being constructed of "pear" configuration with a small protuberance 47 projecting from the coupling pin 26. Each tooth 24' of the toothed belt 23, has a cavity 26' into which the pin 46 is inserted.
The upper pair of support guides 40 which have to support the weight of the flats 7 along their inoperative path are located at a transverse distance apart D 40 (FIG. 6C) substantially equal to the distance D 10 between the guides 10. The projection 47 projects from the teeth 24' such that their contour along the pair of belts 23 remains separated from the guides 40 and does not make contact with them, it being the projection 47 itself, preferably formed of material of good antifriction and antiwear characteristics, which slides on them along the inoperative path of the flats. The flats, which are supported by the pins 27 along the path of the guides 10, are supported along the upper return path of the guides 40 by the pins 46, with reduced friction and wear.
FIGS. 7A, B show a modification of the coupling of FIGS. 6, in which the cavity 26' into which the pin 46 is inserted has a smaller depth than the pin diameter so that, during the inoperative path of the flat, said pin 46 projects from the belts and raises them, analogously to the embodiment of FIG. 6, so that the pin itself slides on the upper guides instead of the teeth of the belts, with substantial reduction in friction.
Although a preferred embodiment of the invention has been specifically illustrated and described herein, it is to be understood that minor variations may be made in the apparatus without departing from the spirit and scope of the invention, as defined the appended claims. | A carding flat and a system for guiding and driving it in a card with moving flats driven by toothed belts, in which coupling between the flats and belts is achieved by a form fit between cavities and projections without fixed retention means, so enabling these elements to freely rotate about the coupling axis. | 3 |
BACKGROUND OF THE INVENTION
1. Field of the invention
This invention provides a padlock; particularly, this invention provides an improved actuating mechanism, which can easily be fixed in place and easily be assembled.
2. Description of the Prior Art
In the conventional padlocks, the coupling part of the cylinder has two actuating blocks, which are movably connected with the cam member. Between the cam member and the cylinder coupling part, there is a spring to enable the cam member to return its original position after the padlock being in locked position.
One end of the aforesaid spring is attached to one of the actuating blocks of the cam member, while the other end thereof is inserted in a small round hole on the wall of the lock body. As a result of the spring force and the space limit outside the cam member, installation of the spring is rather difficult. Since one end of the spring is simply hooked in place, it is susceptible to becoming disengaged from the actuating block; in that case, the lock will be out of order. It is particularly true to happen, when such a padlock is used on a container truck; the reason is that the spring can not be fixed in place securely.
Another prior art is that a spring is mounted between the cylinder coupling part and the cam member of the padlock; the spring is wound around a shaft with a salient block. After the shaft and spring being put in a positioning hole, the spring is movably fixed to the wall of the lock body portion. There is an inner shaft being mounted between the cylinder coupling part and the cam member; the other end of the spring is attached to one end of the inner shaft so as to provide a return force during the lock being unlocked and locked.
According to the aforesaid padlock, a spiral spring is installed between the cylinder coupling part and the cam member, and that padlock also has an inner shaft and outer shaft, whereby there are no drawbacks in assembling operation and to cause the spring to separate from the fixed part thereof in case of being shaken; however, that padlock needs a longer body portion so as to have sufficient space to accommodate the spiral spring, the inner and outer shafts.
SUMMARY OF THE INVENTION
In view of the drawbacks of the conventional padlocks, the inventor has developed a new actuating mechanism, which is substantially an actuating assembly being installed in front of the lock cylinder. The actuating assembly can control the lock shackle during locking or unlocking operation. The actuating assembly mainly comprises a cam member, a front guide plate, a rear guide plate, a T-shaped bolt and a return spring. The cam member has two opposite curved recesses to mount two steel balls respectively, and also has a round hole in the center thereof. The front end of the cam member has two opposite lugs. After mounting the front guide plate, the return spring and the rear guide plate on the T-shaped bolt, the bolt is installed into the center hole of the cam member, and is to be fixed in place with a pin to penetrate into a pin hole on the cam member, and then the actuating assembly is completely assembled. The inner end of the return spring is fixed in a square groove of the T-shaped bolt, while the outer end thereof is movably attached to a cylindrical fixed block, which is movably mounted in a block hole inside the lock body portion. Then, the actuating assembly is installed in place to control the lock shackle to move. The outer end of the T-shaped bolt is coupled with the driving member of the lock cylinder to receive the unlocking and locking force. Since the actuating assembly is a complete unit, which can facilitate the assembling operation of the whole padlock; further, the return spring of the actuating assembly would not be out of order upon being shaken.
The prime object of the present invention is to provide a padlock, in which the actuating assembly is a complete unit comprising a cam member, a front guide plate, a rear guide plate, a T-shaped bolt, and a return spring; the inner end of the return spring is movably attached to a square groove of the T-shaped bolt, while the outer end thereof is inserted in a cylindrical fixed block to prevent the return spring from being disengaged. The actuating assembly can easily be installed inside the body portion during assembling of the lock.
Another object of the present invention is to provide a new padlock, in which the T-shaped bolt of the actuating assembly may have a round or square bolt stem to penetrate the front guide plate, the return spring, the rear guide plate and finally to connect with the cam member. The other end of the T-shaped bolt is formed into a rectangular plate to be engaged with a cylinder coupling part so as to control the actuating assembly.
Still another object of the present invention is to provide a new padlock, in which the return spring is a coiled leaf spring; the inner end of the spring has a bent part to be engaged with the T-shaped bolt, while the outer end thereof has a straight portion to be connected with a cylindrical fixed block which is to be inserted in a block hole inside the body portion of the lock so as to fix the spring in place without becoming disengaged or loose. A further object of the present invention is to provide a new padlock, in which the center of the cam member of the actuating assembly has a round or a square hole for fitting the T-shaped bolt; the cam member has two opposite curved recesses for mounting two steel balls respectively. The inner end of the cam member has two opposite lugs for fitting the rear guide plate and the return spring therebetween. By means of the rear guide plate, the steel balls are separated from the return spring. The rear guide plate is mounted against the outer ends of the two lugs to prevent the T-shaped bolt from affecting the movement of the return spring.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a disassembled view of an embodiment of the present invention.
FIG. 2 is a sectional view of the present invention, showing the lock being in locked up state.
FIG. 3 is another sectional view of the present invention, showing the lock being in unlocked state.
FIG. 4 is a fragmentary sectional view of the actuating assembly of the present invention.
FIG. 5 is a sectional view taken along line A--A of FIG. 2.
FIG. 6 is a sectional view taken along line B--B of FIG. 2.
FIG. 7 is a sectional view taken along line C--C of FIG. 2.
FIG. 8 is a fragmental sectional view of another embodiment of the actuating assembly according to the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIGS. 2 and 3, there is shown a padlock according to the present invention, which mainly comprises a body portion 11, a lock cylinder 12, an actuating assembly 13, and a shackle 15. The actuating assembly 13 and the lock cylinder 12 are mounted in a cylinder hole 14 in the body portion 11. One end of the body portion 11 is furnished with two round holes for receiving the shackle 15. The actuating assembly 13 and the lock cylinder 12 are fixedly fitted in the body portion 11 by means of a screw 18. The shackle 15 is to be set at a locked or unlocked position by means of two steel balls 19 and 20 mounted on both sides of the actuating assembly 13. One of the balls is also used to prevent the shackle from being separated from the body portion 11. The rotation movement of the lock cylinder 12 can set the lock in locking up or unlocked state because of the actuating assembly 13 able to control the two steel balls 19 and 20 to move into the locking up or unlocked position. A spring 21 mounted in a round hole 17 is used to move the shackle in unlocked position upon the shackle being released by the balls.
The actuating assembly 13 as shown in FIGS. 1 to 7 mainly includes a cam member 31, a front guide plate 32, a return spring 33, a rear guide plate 34, and a T-shaped bolt 35; the actuating assembly 13 is fitted in the cylinder hole 14 of the body portion 11, and is to be operated together with the lock cylinder 12.
In the actuating assembly 13, the cam member 31 is a cylindrical member, which includes two curved recesses 41 and 42 for receiving two steel balls 19 and 20 respectively. When the cam member 31 is rotated, the two steel balls 19 and 20 will also be moved to caused the shackle to be set at a locked up or unlocked position. The center of the cam member 31 has a round hole 43, and the edge of the inner surface 51 of the cam member 31 has two lugs 44 and 45. A T-shaped bolt 35 is fitted in the round hole 43 so as to hold the rear guide plate 34, the return spring 33 and the front guide plate 32 together; the bolt stem 50 of the T-shaped bolt 35 has a groove 46, which is exactly aligned with a pin hole 47 on the cam member 31 so as to facilitate a pin 48 to insert therein for assembling the T-shaped bolt 35 and the cam member 31 together. In that case, the rear guide plate 34 is exactly set against the outer ends of the two lugs 44 and 45. The bolt stem 50 of the T-shaped bolt 35 can also be made into a square shape as shown in FIG. 8.
After the actuating assembly 13 that includes the rear guide plate 34, the return spring 33, the front guide plate 32 and the T-shaped bolt 35 is assembled together with the cam member 31, the front guide plate 32 is to be mounted against the inner surface 51 between the two lugs of the cam member 31. The two indented edges 52 of the front guide plate 32 are set against the inner surface 51 of the cam member 31, while the two convex edges 53 are set against the ends of the curved recesses 41 and 42 of the cam member 31 respectively so as to maintain the steel balls in the recesses 41 and 42 respectively.
One end of the T-shaped bolt 35 has a rectangular plate 55 to be mated with a rectangular groove 57 on the driving member 56 of the lock cylinder so as to provide a mechanical coupling function after the lock cylinder 12 and the actuating assembly 13 are assembled together. The bolt stem 50 of the T-shaped bolt 35 has a square groove 58 to be used for retaining the inner end 59 of the return spring 33. When the T-shaped bolt 35 is driven by the driving member 56, the spring 33 will be wound to store a mechanical force, which will provide a return force upon being released.
In the actuating assembly 13, the T-shaped bolt 35 is used to assemble the other parts such as the rear guide plate 34, the return spring 33 and the front guide plate 32 together. The actuating assembly 13, can, upon the lock being unlocked, return to its original position by means of the return spring 33, of which the inner end 59 is fixed in the square groove 58, while the outer end of the spring has a straight portion 60 being embedded in the slot 62 of a cylindrical block 61.
The actuating assembly 13 is installed in the cylinder hole 14 of the body portion 11. Both sides of the cam member 31 are fitted with two steel balls 19 and 20 respectively. In the cylinder hole 14, there is also a block hole 63 for positioning the cylindrical block 61. After all the parts are fitted in the cylinder hole 14, the outer end of the return spring 33 is fixed in place by means of the cylindrical block 61 so as to provide the actuating assembly 13 with a force to return to its original position upon the lock being unlocked.
In the present invention, the return spring 33 is fitted in place, by means of the rear guide plate 34, near the end of the two lugs 45 and 46 of the cam member 31, i.e, the return spring 33 is mounted between the front and rear guide plates 32 and 34 to have sufficient winding or unwinding space.
Another embodiment of the actuating assembly is shown in FIG. 8, in which the cam member 31 is not provided with lugs; the front guide plate 32 and the inner surface 51 of the cam member 31 are in close contact with each other. The return spring 33 is fitted between the front and rear guide plates 32 and 34; after mounting the T-shaped bolt 35 in place, the actuating assembly 13 can also provide the same function in the lock.
Briefly, the actuating assembly of the present invention is coupled with the lock cylinder by means of the T-shaped bolt; then, the return spring is mounted in place by means of a cylindrical block and a block hole in the body portion so as to make the cam member rotating freely during locking and unlocking operation without causing the actuating assembly to become loose or malfunction. The structure of the present invention is deemed practical and novel. | It is an improved padlock structure, in which the actuating mechanism is particularly designed to include a lock cylinder and, an actuating assembly; the actuating assembly further includes a T-shaped bolt, a front guide plate, a rear guide plate, a return spring, and a cam member with two steel balls. The major features of this lock are its single structure and having little or no trouble in use. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
Related Application
This application is a continuation-in-part of co-pending and co-owned U.S. patent application Ser. No. 10/604,443, entitled “ Tornado and Hurricane Roof Tie” , filed with the U.S. Patent and Trademark Office on Jul. 22, 2003 by the inventor herein, which is a continuation-in-part of co-pending and co-owned U.S. patent application Ser. No. 10/211,138, entitled “ Tornado and Hurricane Roof Tie” , filed with the U.S. Patent and Trademark Office on Aug. 2, 2002 U.S. Pat. No. 6,837,019 by the inventor herein, the specifications of which are included herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to building structures with wood roofs, and more particularly to structures exposed to extreme wind conditions, such as Tornadoes and Hurricanes, where building codes dictate that such structures be protected against structural failure to save lives of occupants. In particular, the present invention relates to a roof tie for anchoring a wood frame roof on a block construction building in order to resist uplift forces encountered during a high wind situation.
2. Background of the Prior Art
It is well known what high winds can do to a building, particularly to a wood frame construction low-rise structure. Generally, uplift forces tending to lift the roof off the structure or the entire structure off its foundation cause much of the damage sustained by the building.
Wood structures predominate in residential and light commercial construction, and when wood framing is employed, the structure must be protected from upward loads developed by high wind, which differs with geographical location and is enforced by different building codes for such areas. For example, the Bahamas and Florida, including the Florida Keys are situated in the pathway of the yearly Caribbean hurricane travel course and as such, encounter hurricanes and/or tornadoes from time to time. Houses in the Bahamas are typically constructed of cement block with a wooden top plate fastened to the top of cement block walls, for attaching a wooden roof. In the case of upward loads, the roof is generally tied to the walls using a variety of steel connectors that tie the top plate to the walls. The size and number of these steel connectors vary depending on the severity of the wind conditions in the locality of the building, and the building's geometry. Due to the house location in a susceptible high wind area, some building codes require that houses built with wooden roof support beams have a “Hurricane Tie” in place on every rafter.
“Hurricane Ties” are usually installed during the foundation and framing stages of construction. Carpenters and laborers hired by the framing contractor generally install connectors and sheathing. Correct size, location, and number of fasteners (nails or screws) are critical to sustaining the required load. Commonly, such laborers are inexperienced, which results in improper or inadequate installation. The connectors are usually installed during the framing stage due to related components being placed at the same time. This process slows the foundation and framing stages of construction, which, in turn, increases labor costs.
From the foregoing, it is apparent that there is a critical need for a strong roof tie system that provides for uplift loads, which system is cost effective and easy to install.
SUMMARY OF THE INVENTION
The present invention provides a solution to the above and other problems by reinforcing and anchoring the roof structure to the building top plate for a wood construction building, wherein a hold down force is applied to the ceiling rafters to counter the uplift and horizontal forces generated by high winds. The present invention can be incorporated during initial construction of a wooden roof structure.
It is an object of the present invention to provide a roof-tie bracket system for a wooden roof structure of a building that reinforces the roof against damage in a high wind situation, such as a hurricane.
It is another object of the present invention to provide a roof-tie bracket system for a wooden roof construction building that provides a downward force around the periphery of the roof, thereby to better resist upward lift imparted to the roof by high winds.
It is another object of the present invention to provide a roof-tie bracket system for a wood frame roof that provides reinforcement to the roof structure, thereby providing greater resistance to damage during high wind conditions. A related object is to increase public safety in structures existing in high wind susceptible areas.
It is yet another object of the present invention to enable cost effective construction of wooden roof structures while meeting all building code requirements. A related object is to provide a roof-tie bracket system for a low-rise building that complies with the recommendation of all major building codes.
This invention relates to a novel roof-tie bracket system for bracing a wood framed roof of a building, e.g., a residential dwelling, having a structure including a foundation upon which rests a wall construction and horizontal ceiling top plates. The structure is reinforced against the destructive forces of the atmosphere by high strength brackets preferably attached to every rafter where it joins the ceiling plates. The roof-tie bracket is connected to the structure by way of a plurality of fasteners, such as nails or screws.
The roof-tie bracket disclosed herein offers more body, more nailing surfaces, more wrapping capability, more strength, and more durability to the purchasing public. Such roof-tie brackets may be made from a graduated increase in sheet metal gauges in a variety of straps or ties to fit many framing applications and strength requirements. Moreover, such roof-tie brackets may be pre-pitched to a predetermined angle of a roof, keeping in mind the different sizes of wood that may be used to pitch a roof. Such roof-tie brackets create a solid attachment between a rafter and ceiling top plate. This simple invention enables a family of roof-tie brackets that can be mass-produced and sold for a reasonable price that, in fact, can be made or put in place by any skilled or semi-skilled person.
Some of the advantages of this invention include: increase in surface area of a roof-tie bracket, thereby creating more surfaces through which nails could penetrate the substructure; “prepitched” roof-tie brackets that create a snug fit over all substructures and angles, at angles consistent with industry roof pitch standards; a wide aperture that allows fastening of nails through the roof sheaths to the rafter beneath; “plate flaps” that further secures the roof-tie bracket to the top plate; and, in some embodiments, a “U-shaped ceiling joist structure” that provides further for the “strapping” of ceiling joists, all in one simple Hurricane and Tornado Tie.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other features, aspects, and advantages of the present invention are considered in more detail, in relation to the following description of embodiments thereof shown in the accompanying drawings, in which:
FIG. 1 shows an illustration of a roof tie in perspective, according to one embodiment of the present invention;
FIG. 2 shows an illustration of an alternate perspective of the roof tie of FIG. 1 ;
FIG. 3 shows an illustration of the roof tie in perspective, with top plate and rafter in phantom;
FIG. 4 shows an illustration of an alternate perspective of the roof tie of FIG. 3 , with a top plate and rafter in phantom;
FIG. 5 shows an illustration of a roof tie, according to an alternative embodiment of the present invention;
FIGS. 6 and 7 show an illustration of the roof tie in perspective, according to an additional alternate embodiment of the present invention;
FIG. 8 shows an illustration of the roof tie of FIG. 7 , in perspective, showing a ceiling joist in place;
FIG. 9 shows an end view of the roof tie of FIG. 6 ;
FIG. 10 shows a close-up view of a portion of FIG. 6 ; and
FIG. 11 shows an illustration of a gable end roof tie according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The invention summarized above and defined by the enumerated claims may be better understood by referring to the following description, which should be read in conjunction with the accompanying drawings in which like reference numbers are used for like parts. This description of an embodiment, set out below to enable one to build and use an implementation of the invention, is not intended to limit the enumerated claims, but to serve as a particular example thereof. Those skilled in the art should appreciate that they may readily use the conception and specific embodiments disclosed as a basis for modifying or designing other methods and systems for carrying out the same purposes of the present invention. Those skilled in the art should also realize that such equivalent assemblies do not depart from the spirit and scope of the invention in its broadest form.
Referring to FIGS. 1 and 2 , a roof tie according to the present invention, indicated generally as 10 , is illustrated, comprising a pair of C-shaped tie components 13 , 15 , a U-shaped ceiling joist seat component 17 , and a bridge component 19 . The U-shaped ceiling joist seat component 17 has an upper portion 21 and a lower portion 24 . The upper portion 21 of such U-shaped ceiling joist seat component 17 comprises a wall 28 having a plurality of apertures 30 and at least one fastener slot, such as 32 . The lower portion 24 of such U-shaped ceiling joist seat component 17 comprises fastener extension 35 , which extends at a right angle from wall 28 and further comprises fixed top plate flap 38 , hinged top plate flap 40 , and short wall 43 . The fixed top plate flap 38 further comprises an appendage 44 , described in further detail below. The short wall 43 is disposed on an outward edge of fastener extension 35 and extends upward, substantially perpendicular to such fastener extension 35 . In general, the short wall 43 is preferably shorter than and substantially parallel to wall 28 . A plurality of apertures 30 for inserting fasteners, such as nails, are disposed on such fastener extension 35 , fixed top plate flap 38 , hinged top plate flap 40 , and short wall 43 . Such plurality of apertures should be disposed in a staggered fashion to prevent splitting of the top plate and rafters when inserting such fasteners.
Bridge component 19 presents a wide aperture area 46 to permit fastening decking to a rafter. Such bridge component 19 should be wide enough to conform to the standard thickness of construction materials, such as wooden 2×4s. Bridge component 19 comprises a short riser 48 having a plurality of apertures 30 for fastening such bridge component 19 to a rafter. In some embodiments, bridge component 19 can be counter sunk into the rafter in order to be flush with the top surface of such rafter. Bridge component 19 further comprises an overlap plate 51 disposed away from such bridge component 19 by ledge 53 and having at least one opening, such as 56 . In use, overlap plate 51 at least partly extends over wall 28 . The fastener slots 32 are disposed on wall 28 such that, in use, fasteners inserted in openings 56 in overlap plate 51 can penetrate such fastener slots 32 . By having such overlap, roof tie 10 can adapt to rafters of varying heights for application in a variety of construction scenarios. Fastener slots 32 enable fasteners to be inserted in such a manner to ensure a snug fit for bridge component 19 on the top of a rafter. Overlap plate 51 extends over wall 28 , such that fasteners inserted in openings 56 also enter fastener slots 32 at a variable position depending on the height of the rafter, for attachment to the rafter.
Tie components 13 , 15 present mirror images of each other. Each tie component 13 , 15 has an upper portion 60 and a lower portion 62 . The upper portion 60 of such tie component comprises a riser 65 having a plurality of apertures 30 . The C-shaped lower portion 62 of such tie component comprises fastener extension 67 , which extends at a right angle from riser 65 and further comprises a top plate flap 70 with an appendage 73 . Appendage 73 extends inwardly at a right angle from top plate flap 70 . Top plate flap 70 is sized and configured such that appendage 73 can fit under a top plate to form a three-sided wrap with fastener extension 67 and top plate flap 70 . In some embodiments, top plate flap 70 is sized and configured such that appendage 73 may be embedded into a side of the top plate. In such an embodiment, appendage 73 should penetrate approximately ¾-inch into the wood top plate; the inner edge 74 of appendage 73 may be sharpened to enable such penetration. (Appendage 44 of the fixed top plate flap 38 of such U-shaped ceiling joist seat component 17 is configured in the same manner.) A plurality of apertures 30 for inserting fasteners, such as nails, are disposed on said fastener extension 67 , and top plate flap 70 .
Each tie component 13 , 15 further comprises a turnbuckle 75 attached to bridge component 19 and fastener extension 67 . Turnbuckle 75 comprises body 78 having a first threaded portion 81 extending out of the top of body 78 and a second threaded portion 83 extending out of the bottom of body 78 . Body 78 is internally threaded for mating with such first and second threaded portions 81 , 83 . The distal end of such first threaded portion 81 terminates in an eye 86 having an opening for attaching to short riser 48 of bridge component 19 . The eye 86 can be attached to short riser 48 by a suitable fastener, such as a nail or lag bolt. In some embodiments, short riser 48 presents a hook on which such eye 86 can be attached. In an additional embodiment, short riser 48 presents a track 90 in which an adjustable hook or other appropriate fastener can be variably positioned. The distal end of such second threaded portion 83 terminates in an eye or some other fashion for attachment to plate 93 attached to fastener extension 67 by suitable fasteners.
The alignment of the threads of such first and second threaded portions 81 , 83 is configured such that rotation of body 78 in a first direction about its longitudinal axis causes both such first and second threaded portions 81 , 83 to be drawn into body 78 and rotation of body 78 in a second, opposite direction about its longitudinal axis causes both such first and second threaded portions 81 , 83 to be forced out of body 78 . The roof tie 10 provides additional reinforcement against uplift forces encountered in a high wind condition, resulting in a sturdier, stronger tie. Such increased strength can be obtained at reduced cost by enabling use of lower galvanized steel gauges for its construction while providing increased hold-down force.
Bridge component 19 can be variably pitched and retrofitted to existing roof applications, especially for roof trusses. The turnbuckles can be adjusted, up or down, as necessary to provide sufficient hold down tension and to conform to the pitch of the roof.
For heavy-duty applications, or as an optional feature, roof tie 10 may further comprise a reinforcing wing 95 on tie components 13 , 15 . Such reinforcing wing 95 is generally triangular in shape and extends outward from riser 65 with the lower edge of reinforcing wing 95 attached to the inner edge of fastener extension 67 . Such reinforced roof tie 10 provides vertical reinforcement to prevent balking while enabling increased rigidity to roof tie 10 , resulting in a sturdier, stronger roof tie 10 . The increased strength can be obtained at reduced cost by enabling use of lower galvanized steel gauges for its construction. Balking is caused by misalignment of trusses due to warping of roof timbers or loosening of fastened joints, resulting in roof decking being heaved up along such misaligned roof truss.
An application showing use of roof tie 10 is illustrated in FIGS. 3 and 4 presenting roof tie 10 in a position for fastening to top plate 98 and rafter 99 . Fasteners are attached to top plate 98 and rafter 99 through apertures 30 , and through openings 56 in alignment with fastener slots 32 . Using a fastener in each aperture and opening ensures a strong and secure attachment. Additional embodiments using various numbers of holes can be used based on specific engineering requirements as determined by one skilled in the art.
As shown in FIG. 3 , hinged top plate flap 40 can be rotated into approximately the same plane as fastener extension 35 to enable appendage 44 to be fastened into one side of top plate 98 ; then, hinged top plate flap 40 can be rotated substantially perpendicular to the fastener extension 35 providing a wrap around most of such top plate 98 . Fixed top plate flap 38 and hinged top plate flap 40 are attached to top plate 98 with a plurality of suitable fasteners through apertures 30 . Bridge component 19 straddles rafter 99 and is attached to rafter 99 with a plurality of fasteners, as described above. Wide aperture area 46 is provided to enable fastening of decking material to rafter 99 .
As shown in FIG. 4 , tie components 13 , 15 are attached to top plate 98 to enable appendage 73 to be fastened into each side of top plate 98 . Turnbuckle 75 is attached to bridge component 19 . Fastener extension 35 and top plate flap 70 are attached to top plate 98 with a plurality of suitable fasteners through apertures 30 . If necessary, turnbuckle 75 can be adjusted to provide sufficient hold down tension.
In some embodiments, the length of the forward edge of wall 28 may be longer than the rear edge of wall 28 in order to have bridge component 19 angled to correspond to a selected pitch for a roof. In such cases, the turnbuckles 75 of tie components 13 , 15 can be adjusted to appropriate lengths to conform to the pitch of the roof.
FIG. 5 shows an illustration of an application according to an alternative roof tie embodiment. Roof tie 100 comprises two pair of matching tie components 103 , 105 , 107 , 109 attached to either side of bridge component 112 . Each tie component 103 , 105 , 107 , 109 comprises a riser 115 having a plurality of apertures for inserting fasteners, such as nails therethrough and a fastener extension 117 , which extends at a right angle from riser 115 and further comprises a top plate flap 119 with an appendage 123 . Appendage 123 extends inwardly at a right angle from top plate flap 119 . Top plate flap 119 is sized and configured such that appendage 123 can fit under top plate 125 to form a three-sided wrap with fastener extension 117 and top plate flap 119 . In some embodiments, top plate flap 119 is sized and configured such that appendage 123 may be embedded into a side of the top plate 125 . In such an embodiment, the inner edge 127 of appendage 123 may be sharpened to enable penetration into wooden top plate 125 . A plurality of apertures 130 for inserting fasteners, such as nails are disposed on fastener extension 117 and top plate flap 119 .
Each tie component 103 , 105 , 107 , 109 further comprises a turnbuckle 133 attached to bridge component 112 and fastener extension 117 . Turnbuckle 133 comprises a body 138 having a first threaded portion 141 extending out of the top of body 138 and a second threaded portion 143 extending out of the bottom of body 138 . Body 138 is internally threaded for mating with such first and second threaded portions 141 , 143 . The distal end of such first threaded portion 141 terminates in an eye 146 having an opening for attaching to bridge component 112 . The eye 146 can be attached to bridge component 112 by a suitable fastener, such as a nail or lag bolt. The distal end of such second threaded portion 143 terminates in an eye or some other fashion for attachment to plate 150 attached to fastener extension 117 by suitable fasteners.
The alignment of the threads of such first and second threaded portions 141 , 143 is configured such that rotation of said body 138 in a first direction about its longitudinal axis causes both such first and second threaded portions 141 , 143 to be drawn into body 138 and rotation of body 138 in a second, opposite direction about its longitudinal axis causes both such first and second threaded portions 141 , 143 to be forced out of body 138 . Each turnbuckle 133 on tie components 103 , 105 , 107 , 109 is separately adjustable. Such roof tie 100 provides additional reinforcement against uplift forces encountered in a high wind condition, resulting in a sturdier, stronger tie. The increased strength can be obtained at reduced cost by enabling use of lower galvanized steel gauges for its construction while providing increased hold-down force.
For heavy-duty applications, or as an optional feature, roof tie 100 may further comprise a reinforcing wing 155 on tie components 103 , 105 , 107 , 109 . The reinforcing wing 155 is generally triangular in shape and extends outward from riser 115 with the lower edge of reinforcing wing 155 attached to an edge of fastener extension 117 . Such reinforced roof tie 100 provides vertical reinforcement to prevent balking while enabling increased rigidity to roof tie 100 , resulting in a sturdier, stronger roof tie 100 . The increased strength can be obtained at reduced cost by enabling use of lower galvanized steel gauges for its construction. Balking is caused by misalignment of trusses due to warping of roof timbers or loosening of fastened joints, resulting in roof decking being heaved up along such misaligned roof truss.
Referring to FIGS. 6-9 , an adjustable roof tie 200 is shown. Roof tie 200 comprises a pair of C-shaped tie components 205 , 207 , of similar construction as described with reference to FIGS. 1 and 2 , a bridge component 210 , also of similar construction as described with reference to FIGS. 1 and 2 , and a U-shaped ceiling joist seat component 213 . The U-shaped ceiling joist seat component 213 comprises two slidably engaged connector sections 217 , 219 , each having an upper portion and a lower portion. The upper portion 221 of connector section 217 comprises a wall 224 having a plurality of apertures. The lower portion 226 of connector section 217 comprises fastener extension 229 , which extends at a right angle from wall 224 and further comprises top plate flap 231 . The top plate flap 231 further comprises an appendage 235 that extends inwardly at a right angle from top plate flap 231 . Top plate flap 231 is sized and configured such that appendage 235 can fit under a top plate to form a three-sided wrap with fastener extension 229 and top plate flap 231 . In some embodiments, top plate flap 231 is sized and configured such that appendage 235 may be embedded into a side of the top plate. In such an embodiment, appendage 235 should penetrate approximately ¾-inch into the wood top plate; the inner edge 236 of appendage 235 may be sharpened to enable such penetration. At least one slot, such as 240 , is disposed in fastener extension 229 .
Connector section 219 comprises fastener extension 243 having a short wall 246 disposed on an outward edge of fastener extension 243 , which extends upward, substantially perpendicular to such fastener extension 243 . The lower portion 248 of connector section 219 further comprises top plate flap 251 . The top plate flap 251 is configured similar to top plate flap 231 and comprises an appendage that extends inwardly at a right angle from top plate flap 251 . Top plate flap 251 is sized and configured such that the appendage can fit under a top plate to form a three-sided wrap with fastener extension 243 and top plate flap 231 . In some embodiments, top plate flap 251 is sized and configured such that the appendage may be embedded into a side of the top plate. In such an embodiment, the appendage should penetrate approximately ¾-inch into the wood top plate; the inner edge of the appendage may be sharpened to enable such penetration. Fastener extension 243 overlaps fastener extension 229 . A plurality of apertures 255 for inserting fasteners, such as nails, are disposed on such fastener extension 243 , top plate flaps 231 , 251 , and short wall 246 . Such plurality of apertures should be disposed in a staggered fashion to prevent splitting of the top plate and rafters when inserting such fasteners. Some apertures 255 disposed in fastener extension 243 should align with the at least one slot 240 disposed in fastener extension 229 . By having such overlap, roof tie 200 can adapt to top plates of varying widths for application in a variety of construction scenarios. Fastener slot 240 enable fasteners to be inserted in such a manner to ensure a snug fit for U-shaped ceiling joist seat component 213 on the top plate. Fastener extension 243 extends over fastener extension 229 , such that some fasteners inserted in apertures 255 also enter fastener slots 240 at a variable position depending on the width of the top plate, for attachment to the top plate. When roof tie 200 is attached to top plate 98 and rafter 99 , a ceiling joist 258 can be set in the U-shaped ceiling joist seat component 213 , as shown in FIG. 8 . Fasteners, such as nails or screws can be inserted through apertures 255 to attach roof tie 200 to the ceiling joist 258 .
In some embodiments, both the wall 224 and the short wall 246 may be attached to the same fastener extension, such that the remaining slidably engaged connector section comprises only the fastener extension, top plate flap, and the appendage, for adjustable fit on a top plate.
Tie components 205 , 207 present mirror images of each other. Such tie component 205 , 207 are of similar construction as described with reference to FIGS. 1 and 2 . Referring to FIG. 9 , the C-shaped lower portion of tie components 205 , 207 comprises fastener extension 208 , a top plate flap 209 with an appendage 211 . Appendage 211 extends inwardly at a right angle from top plate flap 209 . Top plate flap 209 is sized and configured such that appendage 211 can fit under a top plate to form a three-sided wrap with fastener extension 208 and top plate flap 209 . In some embodiments, and as particularly shown in FIG. 9 , top plate flap 209 is sized and configured such that appendage 211 may be embedded into a side of the top plate. In such an embodiment, appendage 211 should penetrate approximately ¾-inch into the wood top plate; the inner edge 212 of appendage 211 may be sharpened to enable such penetration.
Referring to FIG. 10 , each tie component 205 , 207 is connected to bridge component 210 by a turnbuckle 260 . Turnbuckle 260 comprises body 262 having a pair of threaded portions 265 extending out of the top and bottom of body 262 . Body 262 is internally threaded for mating with such threaded portions 265 . The alignment of the threads of such threaded portions 265 is configured such that rotation of body 262 in a first direction about its longitudinal axis causes both such threaded portions 265 to be drawn into body 262 and rotation of body 262 in a second, opposite direction about its longitudinal axis causes both such threaded portions 265 to be forced out of body 262 . The outer end of each such threaded portion 265 forms a pivotable attachment 268 to a hinge plate 271 . Hinge plate 271 is hingedly attached to bridge component 210 and tie component 205 , 207 by a hinge and pin assembly 275 .
The backside of a gable end roof tie 300 is shown in FIG. 11 . The front side of such gable end roof tie 300 is similar to the roof tie shown and described with reference to FIG. 3 . In some embodiments, such front side will not include short wall 43 . The remaining portion of gable end roof tie 300 comprises a tie plate 303 and a bridge component 305 having a wide aperture area 308 to permit fastening decking to a rafter. Such bridge component 305 should be wide enough to conform to the standard thickness of construction materials, such as wooden 2×4s. Bridge component 305 comprises a short riser 311 having a plurality of apertures 314 for fastening such bridge component 305 to a rafter.
Tie plate 303 includes an appendage 317 that extends inwardly at a right angle from tie plate 303 . Appendage 317 may be embedded into the butt end of top plate 320 . The inner edge of appendage 317 may be sharpened to enable penetration into top plate 320 . A plurality of apertures 314 for inserting fasteners, such as nails is disposed on tie plate 303 . Tie plate 303 is connected to bridge component 305 by at least one turnbuckle 260 . Turnbuckle 260 comprises body 262 having a pair of threaded portions 265 extending out of the top and bottom of body 262 . Body 262 is internally threaded for mating with such threaded portions 265 . The alignment of the threads of such threaded portions 265 is configured such that rotation of body 262 in a first direction about its longitudinal axis causes both such threaded portions 265 to be drawn into body 262 and rotation of body 262 in a second, opposite direction about its longitudinal axis causes both such threaded portions 265 to be forced out of body 262 . The outer end of each such threaded portion 265 forms a pivotable attachment 268 to hinge plate 271 . Hinge plate 271 is hingedly attached to the short riser 311 of bridge component 305 and tie plate 303 by a hinge and pin assembly 275 . As shown, the turnbuckles can be adjusted up or down, forward or backwards to enable bridge component 305 to conform to a pitched roof and provide sufficient hold down tension.
The invention has been described with references to a preferred embodiment. While specific values, relationships, materials and steps have been set forth for purposes of describing concepts of the invention, it will be appreciated by persons skilled in the art that numerous variations and/or modifications may be made to the invention as shown in the specific embodiments without departing from the spirit or scope of the basic concepts and operating principles of the invention as broadly described. It should be recognized that, in the light of the above teachings, those skilled in the art can modify those specifics without departing from the invention taught herein. Having now fully set forth the preferred embodiments and certain modifications of the concept underlying the present invention, various other embodiments as well as certain variations and modifications of the embodiments herein shown and described will obviously occur to those skilled in the art upon becoming familiar with such underlying concept. It is intended to include all such modifications, alternatives and other embodiments insofar as they come within the scope of the appended claims or equivalents thereof. It should be understood, therefore, that the invention may be practiced otherwise than as specifically set forth herein. Consequently, the present embodiments are to be considered in all respects as illustrative and not restrictive. | A building roof tie for attaching roof trusses and rafters to wood top plates in building structures, said roof tie having a sheet metal body with risers and a bridge for overlapping a rafter and flaps for wrapping on the sides of the top plate. The flaps may be configured to penetrate into the top plate for additional stability. Turnbuckles attached to the bridge provide additional hold-down strength against increased uplift forces. Such turnbuckles may include a hinge and pin assembly that can adjust up and down, forward and backwards. The roof ties are pitched to conform to a variety of framing applications. A plurality of apertures is formed in the roof tie to provide openings for fasteners for connecting the tie to the wood top plate and rafter. | 4 |
BACKGROUND OF THE INVENTION
The invention relates to a transverse pin clevis assembly of a type allowing universal movement between pin grappling elements and being particularly suited for fabrication into relatively large load capacity units.
Prior Art
A clevis with transverse pins can be used to provide pin joint loading in transverse planes in a system to avoid high bending stresses in associated structural elements. Clevises suitable for heavy material handling and the like have been fabricated primarily as forgings, castings, or weldments, depending on physical size, rated load capacity, service environment, production volume, fabrication facilities of a shop, and other factors. Often, the size of a clevis, dictated by its intended design capacity, is so huge that it is beyond the capabilities of otherwise favored forging, casting, or fabrication shops.
The particular application in which a clevis is employed may involve a degree of danger to health and/or property in the event of failure. In such circumstances, it may be customary, and even mandatory, to perform periodic inspections of all related structures to detect premature wear, stress or fatigue cracks and the like. In many instances, particularly where weldments are involved, it may not be possible to detect internal faults in a structure during such inspections. When a defect or a possible defect is uncovered or surmised in a monolithic structure, it is often necessary to discard the entire structure and replace it with a new unit because the defective or suspected area cannot itself be replaced or separately repaired. The safety-related problems are particularly acute in the steel making and processing industry, for example, where loads are extremely high, environmental temperatures affect the serviceability of materials and designs, and the potential danger to personnel and property in the event of failure can be catastrophic.
SUMMARY OF THE INVENTION
The present invention provides a clevis formed as a mechanical assembly of readily fabricated separate parts. The clevis assembly comprises two principal sets of mechanically interlocked components. The first set takes the form of two spaced carrier units strung on a first pin, while the second takes the form of a pair of spreader bars extending between the carrier units. A second pin, transverse to the first pin, is held in aligned holes in the spreader bars.
In the disclosed embodiment, the carrier units are formed as a stack or lamination of separately formed plates. The thickness of the individual laminations may be selected at least in part on the basis of the manner of their fabrication. Where, a disclosed, the laminations have a somewhat irregular profile, such laminations can be successfully formed by flame cutting flat steel stock. As further disclosed, the profile of the carrier unit laminations is arranged to mechanically interlock with the spreader bars to effect and maintain proper relative orientation between these parts without the necessity for significant additional fastener elements or resort to welding.
BRIEF DESCRIPTION OF DRAWING
FIG. 1 is perspective view of a clevis assembly constructed in accordance with the invention;
FIG. 2 is a longitudinal cross-sectional view of the clevis assembly taken in a plane along a primary pin of the assembly; and
FIG. 3 is a transverse view of the clevis assembly taken in the plane indicated by the line 3--3 in FIG. 2.
DESCRIPTION OF PREFERRED EMBODIMENT
Referring now to the Figures, a clevis assembly 10 includes a pair of carrier units 11 strung on a primary pin 12, a pair of spreader bars 13 engaged with the carrier units, and a secondary pin 14 carried on the spreader bars.
In accordance with the invention, the carrier units 11 may be identical in construction and may each be formed of a plurality of separate laminations 17a, 17b, each strung on a pin 12. In the illustrated case, the laminations have substantially the same profile when viewed in the plane of their broad faces. Each lamination 17 is a generally planar body having a U-shaped symmetrical configuration. The legs, designated 18, of the laminations are spaced from one another by a gap 19 and are joined by an integral web 22. The web 22 is formed with a circular hole 23 sized to receive an associated bushing 24 with a press fit. The length of each bushing 24 corresponds to the thickness of the individual lamination 17a, 17b.
At their sides and generally at their midlength, the legs 18 are formed with undercut slots 27 as shown, for example, in the manner of a dovetail. Relief areas 28 in the corners of the slots 27 may be provided to reduce stress concentratons and provide tool clearance for finishing surfaces of the slots. To reduce friction, and thereby facilitate insertion of the spreader bars 13 into the slots 27, additional relief areas 29 may be provided in the slots 27.
With reference to FIG. 2, the separate laminations 17a, 17b may vary in relative thickness, depending on their position, and therefore their functions, in the stack making up the respective carrier unit 11. For example, the innermost laminations 17b of each unit 11 adjacent a gap 31 between units are shown with a thickness relatively greater than that of the remaining laminations 17a. This increased thickness keeps the gap 31 relatively narrow while affording adequate wall thickness (approximately equal to the thickness of the remaining laminations 17a) in the area of a cylindrical recess that provides clearance for the secondary pin 14.
The spreader bars 13 in the illustrated embodiment are generally flat plates of substantially identical construction. The length of the spreader bars 13 as well as the primary pin 12 is generally equal to the sum of the lengths of the carrier units 11 and the intervening gap 31. The width of the spreader bars 13, determined by their beveled edges 34, is substantially equal to the width of the undercut slots 27, thereby permitting the spreader bars to be assembled on the carrier units by longitudinally moving the bars progressively through the associated channels collectively formed by the individual lamination slots 27. Substantially at midlength, a spreader bar 13 is provided with a through crosshole 36 in which is received an end of a second crosspin 14. As shown, the thickness of a spreader bar 13 is generally equal to the minimum depth of the lamination slots 27 and the length of the secondary pin 14 is generally equal to the width of the laminations 17a, 17b, so that in assembly, this secondary pin is supported across the full thickness of each of the spreader bars.
The secondary pin 14 in the illustrated case is retained by a pair of plates 38, one on each of the outer faces of the spreader bars 13, and covering the crossholes 36. The plates are removably secured to the spreader bars 13 by bolts 39 threaded into the spreader bars. Other means for retaining the secondary pin 14 in position, such as setscrews, cotter keys, and other conventional means, are contemplated.
The various elements of the clevis assembly 10 can be fabricated from a variety of materials, both metal and nonmetal, depending on design load, operating environment, type of service and the like. In heavy material handling, the elements can be fabricated from a variety of steels ranging from plain carbon steels, such as ASTM A36, to high quality alloys such as ASTM514,517 or 469.
The disclosed clevis assembly 10 is particularly suitable for applications involving exceptionally large loads such as are involved in material handling in steel mills and the like. For example, the clevis assembly 10 may be used in the system disclosed in U.S. Pat. No. 3,802,730 to Hough by substituting it for the hook support element designated by the numeral 33 in such patent. The particular suitability of the disclosed clevis assembly 10 for a large load capacity applications is derived from its multi-part structure. Each element of its structure can be of a size which is readily fabricated in shops of limited fabrication capacity. While the individual parts are relatively small, and therefore are readily fabricated, they each cooperate with the others to achieve a high load capacity. The U-shaped laminations can be conveniently and economically fabricated by flame-cutting them from flat steel stock. In one assembly designed with a 6:1 safety factor and rated at 215 tons capacity, by way of example, a nominal thickness of two inches in the majority of laminations 17a is used. The primary and secondary pins 12, 14, have diameters in the order of 12 inches. Where the U-shaped laminations 17 are flame-cut, the undercut surfaces, designated 41, and spreader bar contacting surfaces, designated 42, can be finished by secondary machining operations.
The disclosed mechanical assembly of the various parts of the clevis 10 avoids weldments and their attendant uncertainties. Furthermore, the disclosed structure can be disassembled for full inspection of all of the individual components. Any parts which evidence premature wear or questionable structural integrity may be replaced without requiring all of the remaining parts to be discarded. Another important advantage of the laminated structure over a monolithic structure is that any structural fault occurring in one of the laminations cannot readily propagate through the associated remaining laminations. Still another advantage of the lamination structure is that the bushings 24 associated with the primary pin holes 23 are much easier to press in or out for assembly or replacement than would be a single bushing running the full length of a carrier unit 11.
In should be evident that this disclosure is by way of example and that various changes may be made by adding, modifying or eliminating details without departing from the fair scope of the teaching contained in this disclosure. The invention is therefore not limited to particular details of this disclosure except to the extent that the following claims are necessarily so limited. | The invention relates to a clevis structure having transverse pins for a universal coupling effect. The structure is an assembly of mechanically interlocking components which can be individually fabricated and releasably joined without load carrying fasteners, welding, or the like. The components are readily fabricated even in relatively large sizes. | 8 |
BACKGROUND OF THE INVENTION
The present invention relates to a helicopter rotor hub.
Known helicopter rotor hubs are generally constituted by a metal plate having an axial through hole for each blade. Each of these through holes is limited, on the side facing the periphery of the hub, by an arm or bridge which serves as an attachment for the respective blade and permits the centrifugal forces applied by the respective blade to the hub to be transferred to a central shaft.
One of the main disadvantages of the above described known hubs lies in the fact that, because of the monolithic structure of the said bridging arms, partial yielding of one of these automatically involves, in a very short time, the separation of the respective blade.
SUMMARY OF THE INVENTION
The object of the present invention is that of providing a hub which will be free from the above described disadvantage, that is to say a hub in which the forces due to the centrifugal force can follow several alternative routes in such a way that yielding of a part of its structure no longer involves almost immediate separation of a blade.
The said object is achieved by the present invention in that it relates to a helicopter rotor hub of plate-like plan form having a plurality of apertures uniformly distributed about a central axis and each closed radially outwardly by a respective bridge extending peripherally of the said plate permitting the connection of a respective blade to the plate, characterised by the fact that it includes an inner support structure coaxial with the said axis, an outer annular frame extending along the said bridges, and an intermediate lobe structure rigidly connected both to the said inner structure and the said outer frame; the said intermediate structure including a plurality of annular elements each of which comprises a portion extending along a respective said bridge and a further portion connected to the said inner structure.
BRIEF DESCRIPTION OF THE DRAWINGS
Further characteristics and advantages of the present invention will become apparent from the following description with reference to the attached drawings, which illustrate a non-limitative embodiment thereof, in which:
FIG. 1 illustrates in plan a helicopter rotor hub formed according to the principles of the present invention; and
FIG. 2 is a section taken on the line II--II of FIG. 1.
DETAILED DESCRIPTION OF THE INVENTION
FIGS. 1 and 2 illustrate a hub 1 of a helicopter rotor (not illustrated), having in plan the form of a plate with a polygonal perimeter for permitting the connection of a plurality a blades (not illustrated), of which there are five in the illustrated example, to a central shaft (not illustrated).
The hub 1 substantialy comprises an inner support structure 2, preferably metal, coaxial with a central axis of rotation of the hub 1, an outer annular frame 3, preferably made of synthetic fibres and coaxial with the said central axis, and an intermediate lobed structure 4, also preferably made from synthetic material and rigidly connected to the inner structure 2 and to the outer frame 3 to define apertures 4a each of which can receive an attachment element (not illustrated) of a blade.
As illustrated, in particular in FIG. 2, the inner structure 2 includes an annular body 5 positioned with its axis substantially vertically and traversed by an axial hole 6 of cylindrical form. The annular body 5 is provided externally, at its opposite axial ends, with two annular ribs 7 and 8 each having a flat surface 9 coplanar with the associated axial end surface of the body 5 and traversed by a plurality of arcuate outwardly concave channels 10 equal in number to the number of the said blades (not illustrated).
The channels 10 are closed by two annular plates 11 and 12, positioned in contact with the associated surfaces 9 and each connected to the associated rib 7, 8 by means of a ring of screws 13.
The assembly constituted by the annular body 5 and the plates 11 and 12 is preferably made of aluminium and is closed at the top by a cover 14, also preferably made of aluminium and connected to the plate 11 by a ring of screws 15 (FIG. 1). The annular body 5 is supported from below by a tubular body 16, preferably made of metal, and having an upper flange 17 connected to the plate 12 by screws (not illustrated).
As illustrated in FIG. 2, the intermediate structure 4 is composed of an upper portion 18 and a lower portion 19 both of frusto conical form and coaxial with the annular body 5, positioned tapering away from one another with their larger ends in contact across the frame 3.
Each portion 18,19 includes a holder 20 of synthetic material closed outwardly by a cover 21 of synthetic material defining on the interior of the holder 20 a plurality of U-shape channels 22 which are uniformly distributed around the intermediate structure 4 and are disposed radially with respect to this latter and concave towards it. Radially inwardly each channel 22 joins the two adjacent channels 22 to form two radial channels 23 of double width each of which extends towards the inner structure 2 and is disposed with its outer end facing the middle of a peripheral channel 24 perpendicular to the said channel 23 and communicating at its opposite ends with the channels 22 extending from this latter. At the junction of the two adjacent channels 22 with a radial channel 23 the holder 20 is reinforced by an outer covering element 25.
Within each holder 20 are disposed bands 26 of synthetic material, preferably reinforced with axially oriented fibres. Each band 26 has, in plan, the annular plan illustrated in broken outline, a first section 27 of which occupies an associated channel 10 and is connected to two further opposite sections 28 extending along respective channels 23. The free ends of the sections 28 are connected together by a section 29 in the form of the curved broken line extending along an associated channel 22.
As illustrated in FIG. 1 the inner space within each holder 20 not occupied by the bands 26 is occupied by a filling of synthetic material 30. Along their outer peripheries the holders 20 have two annular axial ribs 31 (FIG. 2) defining between them a channel 32 occupied by an annular band 33 constituting the outer frame 3 and extending parallel to the channels 24 and to an outer part of the channels 22.
The bands 33 constitute, together with the outer parts of the bands 26, the bridge structures 34 each of which closes a respective aperture 4a on the outer side and is able to support one of the said blades (not illustrated).
In use the intermediate lobed structure 4 and the outer frame 3 contribute to the uniform distribution of the forces due to the centrifugal force applied by the blades, and transmit these to the inner structure 2.
A particularity of the hub 1 described is constituted by the fact that both the two bands 26 and the band 33 pass through each bridge structure 34. This latter, in the event of breakage of one or of both of the bands 26 of a structure 34, is able to transfer the forces applied to this latter by the centrifugal force to the remaining bands 26 thereby preventing the sudden collapse of the hub 1. | A helicopter rotor hub having a lobed shape defining a plurality of bridge structures each allowing the attachment of a respective blade; each bridge structure is formed of superimposed sections of three annular bands, of synthetic material, the intermediate one of which forms an outer frame extending around the whole of the periphery of the hub, while the other two define one of the said lobes and connect the said outer frame to an inner metal structure. | 1 |
CROSS REFERENCE TO RELATED APPLICATIONS
This invention claims the benefit of priority to U.S. Provisional Application 61/341,250 filed Mar. 29, 2010.
FIELD OF INVENTION
This invention relates to lights, in particular to clip on solar powered light devices, apparatus and methods for clipping on toilet seat lids for illuminating the toilet bowl and surrounding areas after the seat is raised, and the light shut off when the seat is lowered.
BACKGROUND AND PRIOR ART
Many devices have been proposed over the years to illuminate a toilet during the night or in a dark room. See for example, U.S. Pat. Nos. D263,629 to Collins; 4,413,364 to Bittaker; 4,736,471 to Johnson; 4,860,178 to Picon; 5,003,648 to Anderson; 5,150,962 to Rauschenberger; 5,136,476 to Horn; 5,263,209 to Paltee; 5,513,397 to Terry; 5,664,867 to Martin; D382,360 to Bixby; 5,611,089 to Cretors; D397,465 to Youri; 5,819,330 to Yokel; 6,003,160 to Seidle; 7,036,158 to Bradford; and D571,031 to Perkins. See also for example, U.S. Published Patent Applications: 2004/0184273 to Reynolds and 2005/0108819 to Bradford, II et al. However, there are many problems in the prior art.
For example, some prior art devices require the light to be attached to locations that become unsanitary in short periods of time, such as to the rim edges on the toilet bowl, placed directly on the seat and hinged to back of the toilet.
Many of the devices of the prior art require battery only power sources that cannot be recharged and require a constant change of batteries overtime. Additionally, it usually becomes known the battery needs to be changed when the light is not able to turn on during the an actual night-time or dark operating condition, when the light source is most needed to work.
Some of the prior art further requires motion sensing to activate the light source. Some prior art requires large non-aesthetic light sources that appear obtrusive. Some prior art devices require substantial amounts of component assembly and installation and extra time to install. Some of the devices would be expensive to purchase and/or assemble.
Thus, the need exists for solutions to the above problems with the prior art.
SUMMARY OF THE INVENTION
A primary objective of the present invention is to provide novel clip on solar powered light devices, apparatus and methods for toilet seat lids that are simple to install, self contained, low maintenance, solar powered battery run toilet lights.
A secondary objective of the present invention is to provide novel clip on solar powered light devices, apparatus and methods that clamp onto the toilet seat lids, and that will assist people to keep the toilet lid in the down position when not in use.
A third objective of the present invention is to provide novel clip on solar powered light devices, apparatus and methods for toilets that will benefit toilet training, mess prevention and is least subject to unsanitary contamination.
A fourth objective of the present invention is to provide novel clip on solar powered light devices, apparatus and methods for toilets for helping achieve eye adjustment late at night to use the bathroom then returning with uninterrupted sleep.
A fifth objective of the present invention is to provide novel clip on solar powered light devices, apparatus and methods that is nonobtrusive to provide a light in bathrooms so that small children will find the room less frightening, and which gives children the incentive of using the bathroom with confidence when they can see what they are doing.
A sixth objective of the present invention is to provide novel clip on solar powered light devices, apparatus and methods for toilets that is able to provide the elderly with a toilet light device for seeing in the dark in the evening hours or in the middle of the night.
A seventh objective of the present invention is to provide novel clip on solar powered light devices, apparatus and methods for illuminating toilets, that requires no assembly and installation time.
An eighth objective of the present invention is to provide novel clip on solar powered light devices, apparatus and methods for illuminating toilets that only requires clamping the device on the toilet lid, lowering the lid, and allowing for solar light energy to recharge the battery and begin use.
An ninth objective of the present invention is to provide novel clip on solar powered light devices, apparatus and methods for illuminating toilets that is easily transportable, to be moved from one location to another, such as when a person travels to another location with or without children.
An tenth objective of the present invention is to provide novel clip on solar powered light devices, apparatus and methods for illuminating toilets that is easily usable with different sizes and types of toilets.
An eleventh objective of the present invention is to provide novel clip on solar powered light devices, apparatus and methods for illuminating toilets, that is out of the way from being in contact with germs.
The invention relates to a solar toilet light device which clamps on the top of the toilet lid. When positioned up the lid will illuminate the area surrounding the toilet bowl. The toilet seat lid light, comprised by a clamp, which affixes the device on the long side of a metal, preferably stainless steel, clamp, containing the removable power source. The power source and circuit board containing the LED light, and the electrical connection by a ball switch, which is on when the lid is in the upright position.
A photo cell can be located on top of the clamp to let the LED light illuminate when surrounding exterior light has been turned off or during evening or night-time conditions. On the top of the lid, the solar panel charges the battery when light is present on the solar panel. The LED light bulb can be positioned on the front side of clamp as to when on it lights the area in and around the toilet bowl.
When the toilet seat lid is lowered the ball switch, turns the power off to the light. The solar panel and glow are visible. The solar panel charges the battery and the glow is there to make it easy to find the toilet in the dark. The clamp is positioned on the toilet seat lid on the top leading edge and has photo cell to sense light located on the edge. On the inside of toilet seat lid clamp is the light housing containing the battery, circuit board, and ball switch. On the outside of the toilet seat lid clamp is the solar panel for recharging and glow for easy to find in dark situations.
The present new invention provides a solar powered device attached by a clamp which is placed on the top edge of the toilet seat Lid. The underside of device illuminates with a LED light the toilet bowl and seat in addition to the surrounding area of the bathroom, unlike the other inventions that only illuminate the toilet seat bowl. The present new invention will illuminate a glow from the toilet lid light clamp, when lifted it will self illuminate from the battery powered LED light and the absence of light will allow the light to turn on and gently illuminate the toilet area for men, women and children.
When lowered it will automatically switch off. In the lowered position when light is present it will recharge itself from the top of the clamp, on which mounted is a solar panel. The lid clamping method is to keep light from being exposed to unsanitary contaminations and would be universal for every toilet with a lid cover over the seat. By installing this device on to the toilet seat lid the solar light will recharge the battery. The light can be easily clamped on to the toilet lid, the light body is positioned visibly underside the seat lid. When the lid is lowered the other side of the clamp displays the glow and solar panel. The solar panel is to recharge the battery is located on the underside of the clamp.
Further objects and advantages of this invention will be apparent from the following detailed description of the presently preferred embodiments which are illustrated schematically in the accompanying drawings.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 is a perspective view of the toilet lid light device of the present invention clamped to a toilet seat lid on a toilet.
FIG. 2 is another perspective view of the toilet lid light device installed on the top and underside of the toilet lid, representing the placement of light illuminating the toilet bowl and the surrounding area around the bowl.
FIG. 3 is a front view of the toilet lid light device of the preceding figures with a partial cross-sectional view of the interior components.
FIG. 4 is a back view of toilet lid device of FIG. 3 showing the solar panel, back panel, and screws to hold the panel in place.
FIG. 5 is a side cross-sectional view of toilet lid device of FIG. 4 showing the interior components.
FIG. 6 is an electrical schematic of the toilet lid device with circuit board components.
FIG. 7 is another perspective view of the lid attached toilet lid device with the lid in a down position.
FIG. 8 is another perspective view of the lid attached toilet lid device with the lid in a fully raised position.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Before explaining the disclosed embodiments of the present invention in detail it is to be understood that the invention is not limited in its applications to the details of the particular arrangements shown since the invention is capable of other embodiments. Also, the terminology used herein is for the purpose of description and not of limitation.
A listing of the components will now be described. Listed below is a guide in which the mechanical components match the device. Numbers are as following reference to FIG. 1-6 ;
10 -Light Device 20 -Battery (One Double AA) 30 -Circuit Board 31 -Condenser 50 volt 2.2 32 -LED (white LED preferred) 33 -Resistor 200 ohm 34 -DIOAD 35 -Solid State Relay 36 -Photocell circuit side 37 -Resistor 51K 38 -Switched side of relay 39 -Pos switched side of circuit board 40 -Positive battery side of circuit board 41 -negative side of circuit board 42 -LED power side of circuit board 50 -Stainless steel clamp 52 -first leg 53 -connecting midportion 54 -second leg 60 -Solar Panel 61 -Metal Screws 62 -Back panel to hold battery 63 -Mounting hole 64 -Solar panel DIOAD 70 -Photocell for light switch 75 -Connector Wire 80 -plastic body mold housing 90 -spring in side battery case to hold battery in place 95 -mercury switch 96 -contact point circuit board 100 -Toilet/Toilet Bowl 110 -Toilet Seat 111 -Interior of toilet bowl 120 -Toilet Seat Lid
FIG. 1 is a perspective view of the toilet lid light device 10 of the present invention clamped to a toilet seat lid 120 that is hingedly attached to a toilet 100 . The solar lid light device 10 is intended to be removably clamped to the top edge of toilet lid 120 . When the toilet lid 120 is in an upright position, light is emitted from LED 32 in the direction of the interior 111 of the toilet bowl 100 and also around the exterior of the toilet 100 and on the toilet seat 110 .
FIG. 2 is another perspective view of the toilet lid light device 10 installed on the top and underside of the toilet lid 120 , representing the placement of light illuminating the toilet bowl 100 and the surrounding area around the bowl 100 . The solar panel 60 is shown facing upward and outward and the components inside the device 10 are facing on the underside of toilet lid 120 .
FIG. 3 is a front view of the toilet lid light device of the preceding figures with a partial cross-sectional view of the interior components. Device 10 is shown with the clamp 50 on top, visible photo cell light 70 , attached to a stainless steel device to house the circuit board 30 and its components, which include battery 20 , LED 32 and Mercury switch 95 and contact 96 on the circuit board 30 .
FIG. 4 is a back view of toilet lid device 10 of FIG. 3 showing the solar panel 60 , battery closing back panel 62 , and screws 61 to hold the panel 62 in place. FIG. 5 is a side cross-sectional view of toilet lid device of FIG. 4 showing the interior components.
Referring to FIG. 4 and FIG. 5 , the device 10 removably attaches to the underside 120 of toilet seat lid by the clamp 50 . Screws 61 are provided to remove the cover 62 of the housing in order to access the internal components of the circuit board as well the battery 20 .
Referring to FIG. 5 , the side view of device 10 showing the solar panel 60 attached to leg 54 of the stainless steel clamp 50 which is attached to the front side components such LED 32 , battery 20 , and the circuit board 30 . Back side showing the screws 61 which secure the back panel 62 which secures the battery 20 in place. The stainless steel clamp 50 can also has the photocell and connector wire 75 attached.
Referring to FIG. 4 and FIG. 5 , the lid light device 10 can be clamped on the top of toilet lid 120 by clamp 50 that can be a formed from a bent or U-shaped stainless steel having a first leg 52 and a second leg 54 with connecting midportion 53 therebetween. Each of the legs 52 and 54 can have a rectangular configuration and have a width of approximately 2 to approximately 5 inches and each leg can have a thickness of approximately ⅛ to approximately ¼ inch thick. The second leg 54 is substantially shorter in length than the first leg 52 . For example, the second leg 54 can have a length of less than half the length of the first leg 52 . For example, if the first leg 52 is approximately 7 inches long, the second leg can be approximately 2½ inches long. The second leg 54 can be parallel to the first leg 52 or have an outer end slightly inwardly bent. The clamp 50 can be malleable to clamp onto the edge of a toilet seat lid. Alternatively, the clamp 50 can be one piece molded from plastic and the like.
Referring to FIGS. 3 and 5 , spring 90 is inside the cover 62 and is used to hold the battery 20 in place. A housing 80 such as a plastic body mold housing can enclose the components that include the battery 20 .
FIG. 6 is an electrical schematic of the toilet lid device 10 with circuit board components. The battery 20 stores the power for the circuit board 30 (CB) the battery 20 is charged by the solar panel 60 which has a diode 64 to prevent power loss from solar panel 60 . The battery 20 powers the circuit board 30 through the positive battery side 40 of the circuit board 30 and the negative side 41 of the circuit board 30 . When power comes through the circuit board 30 it comes through positive side 40 on the circuit board 30 to the mercury switch 95 . When the mercury switch 95 is in the upright position, the mercury switch 95 closes and lets power go to side 96 side of board 30 and sends power through the positive switched side 39 of the circuit board (CB) 39 to the solid state relay 35 and continues to the photo cell 70 that senses light in the area of the lid light device 10 .
When the photo cell 70 does not sense light it sends power through photocell circuit side 36 with the help of resistor 33 to the solid state relay 35 and closes the solid state relay 35 . (Resistor 37 helps energize the power side (positive side 42 ) of the LED 32 ). This sends power through the switched side 38 of the relay 35 to the diode 34 which prevents power from back feeding the solid state relay 35 . And in conjunction with the condenser 31 the LED 32 will illuminate with the ground side 41 of the circuit board 30 to the negative side 41 of the circuit board 30 , and back to the said battery 20 . When exterior light is present, the solar panel 60 continuously charges the battery 20 . Light can come from sunlight and/or incandescent light or fluorescent light sources.
FIG. 7 is another perspective view of the lid attached toilet lid device 10 with the lid 120 in a down position. FIG. 8 is another perspective view of the lid attached toilet lid device 10 with the lid 120 in a fully raised position.
Referring to FIG. 7 and FIG. 8 , when the toilet lid 120 is in the lowered position (horizontal), the mercury switch 95 is open and the LED 32 is powered off. Lifting the toilet lid 120 to the upper raised position (vertical), causes the mercury switch 95 to close allowing power 96 to activate the LED 32 to emit light. Lowering the lid turns the switch 95 to an open position turning the LED 32 off.
Although a mercury switch is described, the invention can work with other types of switches, such as a metal ball and contact switch and other types tilt switches, and the like.
While the device is described as having one white LED, the invention can use colored LEDS, and can have plural LEDs as needed. While the battery is listed as a double AA battery, the invention can be powered by other batteries such as but not limited to AAA batteries, nine volt batteries, and the like. While the preferred device is shown as an attachable device to toilet lids, the invention can be molded into a toilet lid as one piece with the lid, where the device cannot be separately removed.
Although the described embodiment is described as using stainless steel, the invention can be done in other materials, such as but not limited to molded plastic and the like.
While the invention has been described, disclosed, illustrated and shown in various terms of certain embodiments or modifications which it has presumed in practice, the scope of the invention is not intended to be, nor should it be deemed to be, limited thereby and such other modifications or embodiments as may be suggested by the teachings herein are particularly reserved especially as they fall within the breadth and scope of the claims here appended. | Devices, apparatus, and methods of using a solar powered, battery operated, light sensitive toilet seat LED (light emitting diode) lid light device that removably clamps to an edge of the outside toilet seat lid. A solar panel is visible on outside of toilet seat is used to recharge a battery in the device. The underside of device contains the secured battery, circuit board, mercury switch and photocell. When the lid and device are in upright position the mercury switch closes. The photocell senses absence of light and the LED light illuminates the toilet bowl and surrounding area. | 5 |
CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation of pending U.S. patent application Ser. No. 12/959,044, filed on Dec. 2, 2010, which is herein incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
This invention relates to a method and apparatus for repairing the wall of a manhole. More particularly, but not exclusively, it relates to a method and device for treating the wall of a manhole using a bladder and material capable of curing and hardening, such as a grout or thermoset resin. The bladder expands to conform to the wall of the manhole and the material capable of curing and hardening is disposed between the wall and the bladder or on the interior surface of the bladder.
Conventional manholes include a lower or bottom panel, a barrel having a relatively constant diameter adjacent the panel, a concentric or eccentric cone extending upwardly from the barrel, one or more adjusting rings to adjust the overall height of the manhole, and a casting frame on top of the adjusting rings to support an elevation substantially level with the surrounding pavement. The casting frame is preferably sealed to the uppermost adjusting ring to preclude or minimize water flow into the manhole. The cone and adjusting rings are commonly known as the manhole chimney. Most manhole structures are unique in size and shape with varying diameters and depths. Also, bricks often form a portion of the wall of the manhole.
Substandard construction methods can lead to damage or deterioration of the manhole structure. Thus the manhole is vulnerable, allowing water and subsidence of soil to enter the manhole, which eventually leads to a structural failure of the manhole.
One presently known method of repairing manholes is the placement of a coating of a cementitious grout onto the interior surface of the manhole wall. The grout is applied in an uncured state and is permitted to cure. Methods of applying the grout include troweling the grout onto the wall of the manhole after spraying or slinging the grout onto the wall of the manhole. The manhole wall must be clean and free from water leaking through the manhole walls. Here, it is necessary for a person to enter into the manhole to plug water leaking into the manhole. A final troweling step is usually required by a person entering the manhole in order to obtain the desired compaction, surface and thickness for the curable and/or hardenable material.
Additionally, resin, such as an epoxy, a polyurethane, polyuria or other thermo-set resins have been applied to manhole walls by spraying or slinging the polymer onto the manhole wall. The polymer requires the manhole wall to be clean and free from water leaking with a prepared surface adequate for adhering the polymer to the manhole wall.
Resin-coated sleeves have also been used for repairing a manhole chimney. However, to accommodate changes in diameter of the manhole, the use of an impermeable coating on the sleeve is problematic, as a substantial coating can prohibit the necessary stretching of the sleeve, because when the sleeve stretches, the coating becomes prone to delamination from the sleeve. Furthermore, applying a coating to a fabric sleeve and sealing the seam of a fabric sleeve increases the cost for producing the sleeve. As such, problems remain in the art and a need exists for an improved method and means for repairing the wall of a manhole.
SUMMARY OF THE INVENTION
It is therefore a principal object, aspect, feature or advantage of the present invention to provide an apparatus and method for repairing the wall of a manhole which improves over or solves the problems and deficiencies in the art.
Other objects, features, aspects, and/or advantages of the present invention relate to an apparatus and method which achieves the desired compaction, surface and thickness for the curable and hardenable material without troweling or otherwise requiring an operator to enter the manhole.
Further objects, features, aspects, and/or advantages of the present invention relate to a new method of repairing the wall of a manhole wherein the curable and hardenable material is applied to the wall and an impermeable coating is applied to the outer surface of the material.
Further objects, features, aspects, and/or advantages of the present invention relate to a new apparatus and method for repairing the wall of a manhole wherein an impermeable coating is mechanically bonded to the grout or other curable and hardenable material.
Still further objects, features, aspects, and/or advantages of the present invention relate to a new method of repairing the interior wall of a manhole wherein an impermeable coating is formed about the manhole wall and adhered thereto with a chemical bond, or in some cases a mechanical and a chemical bond.
Still further objects, features, aspects, and/or advantages of the present invention relate to a new method of repairing the interior wall of a manhole wherein a resin impregnated sleeve does not include an impermeable coating maximizing stretching of the sleeve, forming an impermeable coating to the resin impregnated sleeve by adhering an inflatable bladder to the resin impregnated sleeve as the resin cures.
A still further object, feature, aspect and/or advantage of the present invention relates to a method and apparatus for repairing the wall of the manhole that accommodates diameter changes along the wall.
Further objects, features, aspects, and/or advantages of the present invention relate to a method and apparatus for repairing the wall of a manhole wherein a pressurized, expandable bladder provides a clean dry surface onto which a curable and hardenable material is applied.
These and other objects, features, aspects, and/or advantages of the present invention will become apparent with reference to the accompanying specification and claims.
One aspect of the invention includes a method for repairing a wall of a manhole that obviates the need for a pre-formed liner. The method generally includes applying a material capable of curing and hardening to the wall of the manhole, positioning a bladder at least partially within the manhole, expanding the bladder under pressure against the wall of the manhole, allowing the material to cure and harden, and removing the bladder from the manhole.
In another aspect of the invention, a resin impregnated sleeve may optionally be used and the bladder is left within the manhole after the curing process. A bond is created between the resin and an exterior surface of the bladder after the resin impregnated sleeve is applied to the wall of the manhole and is allowed to cure and harden. In one form, the exterior surface of the bladder is uneven and adapted to be mechanically attached to the cured resin impregnated sleeve. In another form, the bladder is compatible for adhesion with the cured resin impregnated sleeve. Once the material cures and hardens, a mechanical bond and/or a chemical bond are created between the resin impregnated sleeve applied to the wall and the inflation bladder. The bladder is left bonded to the material on the wall of the manhole to create an impermeable coating.
Another aspect of the present invention includes a method of repairing a wall of a manhole wherein a bladder is positioned at least partially within the manhole and expanded under pressure against the wall of the manhole. A material capable of curing and hardening is then applied to the interior surface of the manhole and allowed to cure and harden. The bladder provides both an impermeable barrier and a clean dry surface on which to apply the curable and hardenable material.
Yet another aspect of the present invention relates to an apparatus for treating a wall of a manhole that includes a material capable of curing and hardening covering the wall of the manhole, a bladder is expanded outwardly with an exterior surface of the bladder being attached to the material on the wall of the manhole and wherein the exterior surface of the bladder creates a mechanical bond, a chemical bond, or both a chemical and mechanical bond with the material on the wall of the manhole.
In an alternative form, the apparatus includes a bladder expanded outwardly against the wall of the manhole and the material capable of curing and hardening covers an interior surface of the bladder.
The present invention as disclosed herein provides numerous advantages. For example, once a grout or other material capable of curing and hardening is applied to the wall of the manhole, no troweling by hand or similar operation is required to provide for the proper compaction, surface and thickness of the material. A pre-formed liner is not required to practice the invention. In embodiments wherein the bladder is not removed from the wall of the manhole, the bladder effectively becomes an impermeable barrier or coating to the manhole lining.
Still further yet, in those embodiments wherein the material capable of curing and hardening is sprayed or otherwise applied to the interior of an expanded bladder within the manhole, the bladder provides a clean surface onto which to adhere the material in addition to an impermeable barrier.
Still further yet, the use of an expandable bladder to press a curable and hardenable material against and into cracks and crevices in the wall of the manhole provides for a structurally sound repair not heretofore possible with the prior art spraying and troweling method.
These and other benefits and advantages of the invention will become apparent to those skilled in the art based on the following disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sectional view of a manhole including a sprayer for applying a curable and/or hardenable material onto the manhole walls.
FIG. 2 is a sectional view of a manhole where an installation assembly is used in accordance with an embodiment of the present invention.
FIG. 3 is a sectional view of the manhole in FIG. 1 , showing a second view of the preferred embodiment of the present invention.
FIG. 4 is a sectional view according to line 4 - 4 of FIG. 3 .
FIG. 5 is a sectional view according to line 5 - 5 of FIG. 2 .
FIG. 6 is a sectional view similar to FIG. 5 of a modification of the present invention.
FIG. 7 is a sectional view similar to FIG. 5 of a further modification of the present invention.
FIG. 8 is a sectional view similar to FIG. 5 showing a further modification of the present invention.
FIG. 9 is a sectional view showing yet a further modification of the present invention.
FIG. 10 is a sectional view of the manhole of FIG. 1 showing another embodiment of the installation assembly of FIG. 2 .
FIG. 11 is a sectional view according to line 11 - 11 of FIG. 10 .
FIG. 12 is a sectional view of a manhole illustrating an alternative embodiment of the present invention.
FIG. 13 is a sectional view of a manhole illustrating an alternative embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A typical manhole 10 has a bottom panel 12 that has a run through 13 . The bottom panel 12 is attached to a barrel 14 , a cone section 16 , and a plurality of adjusting rings 18 . A casting frame 20 is mounted at the upper end of the manhole 10 . As can be seen in FIGS. 1, 2, 3, 10, 12, and 13 , the manhole 10 has a number of diameters D 1 , D 2 , D 3 , and D 4 , as well as irregularities in the wall usually formed of brick, which often become spaced from one another.
FIG. 1 shows the initial manhole 10 . A curable and/or hardenable material 42 is sprayed on the wall of the manhole 10 by a sprayer 50 . The material capable of curing and hardening may be a grout, a resin, a thermoset resin, a photocuring resin, or a cementious material. Sprayer 50 has an inside air supply 44 and an outside air supply 46 , which cause sprayer ribs 52 to rotate and throw the curable and/or hardenable material 42 outwardly in the direction of arrow 54 . The sprayer 50 has a feeder 48 which extends downwardly through sprayer 50 . The arrow 56 shows the movement of sprayer 50 in an upward and downward direction. A cementitious grout is preferred, but various construction grouts and resinous materials are suitable for use with the present invention, including resin grouts and thermoset resins such as epoxy resin.
FIGS. 2-4 show an embodiment of the invention. Attached to an upper rack 22 is the upper end 24 of an expandable bladder 26 which extends to a lower end 28 . The lower end 28 of the bladder 26 is attached to a lower rack 30 . The lower rack 30 is attached to the upper rack 22 by a post 32 that has a post section 34 telescopically received within a post section 36 , which has a pin 38 securing the post sections 34 , 36 together. There may be other post sections in addition to post sections 34 , 36 . A threaded end 40 is within the lower most post section 36 so as to secure the post 32 to the lower rack 30 . Alternatively, the bladder 26 may be attached to the upper rack 22 at the upper end 24 of the bladder 26 , and the lower end 28 of the bladder 26 may be closed by banding or otherwise sealing the lower end 28 . In such an alternative, the lower rack 30 and post 32 need not be used to install the bladder 26 into manhole 10 .
The bladder 26 is self-contained and therefore inflatable. The bladder 26 may generally be described as an inflatable, expandable, non-absorbent, fluid impervious film. The bladder 26 is preferably made of thermoplastic polyurethane or another thermoplastic material such as poly vinyl chloride or polypropylene. The bladder material should have a wall thickness of approximately 20-100 mils prior to expansion, which thins to approximately 10-80 mils when expanded against the wall. It is also preferable that the bladder not have a scrim reinforcement, so that the bladder can expand or stretch as necessary to accommodate changes in diameter of the manhole. As such, the bladder 26 may have a single, uniform diameter. With such a bladder, the diameter may be sized to be equal or less than the smallest cross section found within the manhole 10 , which is typically defined by the casting frame 20 and adjusting rings 18 .
An air inlet tube 39 extends through the upper rack 22 and is adapted to introduce air to inflate the bladder 26 . The air inlet tube 39 or a separate inlet may be used to introduce steam or another heated fluid when thermoset resins are used. Alternatively, a UV light may be integrated into the upper rack 22 so as to extend into the bladder 26 .
FIG. 5 shows the bladder 26 with an exterior surface 60 in contact with a curable and/or hardenable material 42 . As shown in FIG. 5 , there are no projections extending from the bladder 26 into the curable and/or hardenable material 42 , and consequently there is no mechanical bond. However a chemical bond exists between the bladder 26 and the curable and/or hardenable material 42 upon the curing and hardening of the material, forming an impermeable coating or barrier that becomes an integral part of the manhole. In order to exploit this feature of the invention, it is preferred to use a bladder material that is compatible for adhesion with the curable and hardenable material. A preferred combination to create a chemical bond is the use of an epoxy as the curable and hardenable material and the use of thermoplastic polyurethane as the bladder material. However, other combinations are within the scope of this invention. The bladder 26 as illustrated in FIGS. 6-9 is intended for use in applications where the bladder 26 remains fixed to the curable and/or hardenable material 42 after it cures and hardens, thus becoming an impermeable coating or barrier by a mechanical bond. Here, the exterior surface 60 is uneven and preferably includes a plurality of projections or protrusions. Referring to FIG. 6 , a surface 60 of the bladder 26 includes straight pointed projections 62 extending in opposite directions and embedded in curable and/or hardenable material 42 . FIG. 7 shows a plurality of curved pointed projections 64 , and FIG. 8 illustrates T-shaped projections 66 . All of these projections 62 , 64 and 66 provide a mechanical bond between the bladder 26 and the curable and/or hardenable material 42 , as the projections become embedded and trapped within the curable and/or hardenable material 42 once the curable and/or hardenable material cures and hardens. Projections having other shapes can be used to create a mechanical bond between the bladder 26 and curable and/or hardenable material 42 .
The projections depicted in FIGS. 6-8 may be formed when the bladder material is made by an extrusion process. In such a process, raw material for forming the bladder is extruded through a series of rollers and allowed to set. At least one of the rollers may be embossed with a texture to impart the projections onto the material.
FIG. 9 illustrates an alternative embodiment of the bladder 26 that is intended for use in applications where the bladder 26 remains fixed to the curable and/or hardenable material 42 after it cures and hardens, thus becoming an impermeable coating or barrier via a mechanical bond. In this embodiment, the mechanical bond is formed by the use of pores 67 within the bladder 26 . The pores 67 may be formed within the bladder material by an extrusion process or like as described above, or the pores 67 may be formed by stretching or abrading the material of the bladder 26 . The stretching may be performed by inflation and expansion of the bladder 26 after placement within the manhole. In operation, the pores 67 are formed within the material of the bladder 26 . The bladder 26 is expanded against a manhole wall. As the material of the bladder 26 stretches, the pores 67 open to accommodate the flow of curable and hardenable material within the pores 67 . The curable and hardenable material cures within the pores 67 and anchors the material of the bladder 26 to the wall of the manhole.
The method of repair illustrated in FIGS. 1-4 is as follows. First, the manhole 10 is sprayed by sprayer 50 , such as shown in FIG. 1 . The sprayer 50 is passed upwardly and downwardly as shown by arrow 56 until the surface area of the wall 43 is covered. The thickness may vary depending upon the condition of the manhole 10 .
The installation assembly, comprising the upper rack 22 , the optional lower rack 30 , and the bladder 26 , is inserted into the manhole 10 with the post 32 threaded into the lower rack 30 . Initially the bladder 26 hangs loose within the manhole 10 and is not in contact with the curable and/or hardenable material 42 . The bladder 26 is then inflated by introduction of a fluid into the fluid intake 39 . Because the bladder 26 is expandable, it moves into contact with the curable and/or hardenable material 42 as shown in FIG. 2 . The fluid can be hydraulic fluid, water, or air, and could be other fluids as well.
The bladder 26 presses against the curable and/or hardenable material 42 so as to smooth it and also to cause the curable and/or hardenable material 42 to press against the number of diameters D 1 , D 2 , D 3 , and D 4 (as well as other diameters) and to penetrate cracks and crevices in the wall of the manhole 10 . This is superior to troweling, which cannot achieve the same penetration of the curable and/or hardenable material 42 . Troweling also requires the operator to enter the manhole 10 . With the present method of operation, it is not necessary for an operator to enter the manhole 10 .
The curable and/or hardenable material is then cured and hardened within the manhole 10 . The curable and/or hardenable material may be cured by the accepted method known for curing the material. For example, the curable and/or hardenable material may be cured by the use of introducing steam within the bladder 26 for a thermoset resin or the introduction of a UV light or the like for a photocuring resin. Once the curable and/or hardenable material 42 has cured and hardened, the bladder 26 may be entirely removed from the manhole 10 or the portion contacting the curable and/or hardenable material 42 may be left in place. In applications where the bladder 26 is removed, it is preferable to use a non-stick bladder material as disclosed in U.S. Patent Publication No. 2009/0194183, which is incorporated herein by reference in its entirety. In such an embodiment, no projections or protrusions should be disposed on the exterior surface of the bladder 26 to ensure the bladder 26 does not stick to the curable and/or hardenable material 42 . Using this particular repair or treatment method, the curable and/or hardenable material is smoothed and penetrates cracks and crevices in the wall of the manhole 10 . However, it is preferred to leave the bladder 26 within the manhole 10 to use it as an impermeable coating or barrier. Here, the bladder 26 is cut adjacent the upper end 24 and the post is unthreaded from its attachment to lower rack 30 . The installation assembly, including the upper and lower rack 22 , 30 and the post 32 , is removed from the manhole 10 to form the manhole lining.
This leaves the manhole 10 as shown in FIG. 3 . A handle 96 with a knife 98 is inserted and the knife 98 cuts the bottom of the bladder 26 into a circular cutout 99 . The excess bladder material is removed from the bottom of the manhole 10 , and the resulting manhole 26 is shown in FIG. 4 . The handle 96 may or may not be utilized, as it allows an operator to stand outside of the manhole while cutting and removing excess material. Alternatively, the operator can enter the manhole 10 to cut and remove excess material. Alternatively, a saw, grinding tool, sander, or other cutting tool may be used to remove or smooth excess or unneeded portions of the bladder and cured material. It should also be noted that the FIGS. 3-4 illustrate where the bottom of the bladder is cut out around the periphery of the floor of the manhole 10 . However, the lining of the entire manhole floor need not be removed. As such, the knife 98 or other cutting tool may simply be used to remove the lower rack 30 and to reinstate access to the run through 13 . Similarly, the knife 98 or other cutting tool may be used to remove excess bladder and other material extending above the casting frame 20 of the manhole 10 after installation of the manhole lining.
As an alternative to positioning the stretchable material or bladder 26 in the manhole and then expanding it radially outwardly toward the manhole wall, it may also be inverted into the manhole. This is illustrated in FIG. 10 wherein an inverter 72 is self-contained within an above ground inverter 74 , and a bladder 82 is within the above ground inverter 74 and is reversed with its outside presented inwardly and its inside presented outwardly.
A plug 76 is inserted within and attached to the above ground inverter 74 . The plug 76 contains a fluid introducer 78 and a pull rope 90 having a lower end 92 and an upper end 94 . The upper end 94 extends through a hole in the plug 76 . Fluid introducer 78 may be used to introduce steam or another heated fluid where thermoset resins are used. In such an application, the use of a heated fluid will permit or encourage curing and/or hardening of the thermoset resin. Alternatively, a separate inlet or port may be integrated into the plug 76 to accommodate the use of a heated fluid.
A rigid ring 80 is placed within the casting frame 20 and an upper end 84 of the bladder 82 is attached to the rigid ring 80 . A lower end 86 of the bladder 82 is attached to a pull device 88 . The lower end 92 of the pull rope 90 is attached to the pull device 88 for embodiments where the bladder 82 is removed from the manhole 10 . The pull rope 90 may also be utilized for embodiments where the bladder 82 is left within the manhole 10 . In such applications, the pull rope 90 may be marked at the upper end 94 prior to the inversion process so that a technician may be able to determine when the bladder 26 is fully inverted into the manhole.
The bladder 82 is reversed or inverted into the manhole 10 with its inside presented outwardly and its outside presented inwardly. The inversion can be caused by a fluid (either gas, air, or hydraulics) that is introduced by the fluid introduction device 78 . The bladder 82 expands into contact with the curable and/or hardenable material 42 . If a photocuring resin is used with a UV light or the like, then the bladder 82 should be made from a translucent or semi-transparent material (as known in the art). This allows a UV light to be lowered into the manhole for curing.
The bottom portion of the bladder 82 can be cut out (as previously described) and removed from the manhole 10 by pulling on the end 94 of rope 90 . The remaining portion of the bladder 82 is left within the manhole 10 . The same modifications as shown in FIGS. 5-8 can be applied to the bladder 82 and the curable and/or hardenable material 42 to create a chemical bond 61 or a mechanical bond or both. Again, the inflatable bladder 82 or other stretchable material acts as a coating on the curable and/or hardenable material 42 .
A second embodiment is illustrated in FIG. 12 . In this embodiment, a manhole liner 100 is used as an alternative to the sprayer 50 and the bladder 82 is left in the manhole 10 to create an impermeable barrier on the walls of the manhole 10 . The manhole liner 100 is generally a fabric capable of being impregnated with a curable and hardenable material. The manhole liner 100 may be a stretchable sleeve that can be used to repair and renew manholes having various sizes. In one embodiment, the manhole liner 100 is a one-size fabric liner which stretches circumferentially to various diameters up to 150% of the unstretched diameter for use in manholes of varying sizes and shapes. U.S. Pat. No. 7,670,086 and U.S. Pat. App. No. 2010/0018631 describe such liners and are incorporated by reference in their entireties.
Where the bladder 82 is to be left within the manhole 10 by the use of a chemical bond, the bladder 82 is preferably constructed of a polyurethane and the curable and hardenable material is preferably an epoxy. However, other combinations of bladder material and material capable of curing and hardening are considered for use as long as they are compatible and conducive for adhesion. Where the use of a mechanical bond is desired, the material of the bladder 82 should include the projections or pores as described above.
In operation of the second embodiment, the manhole liner 100 is impregnated with a material capable of curing and hardening. The manhole liner 100 is then placed into the manhole 10 by attaching an upper portion 70 of the manhole liner 100 to a flange member 68 above the manhole 10 , adjacent the casting frame 20 . The manhole liner 100 is then inserted into the manhole 10 and placed against the walls of the manhole 10 by a bladder 82 that is used to expand the manhole liner 100 against the walls of the manhole. In the embodiment depicted in FIG. 12 , the bladder 82 is inverted into the manhole 10 by attaching the bladder 82 to an above ground inverter 74 , inserting the plug 76 , and providing a fluid to the bladder 82 using fluid introducer 78 . The pull rope 90 may be used to measure the depth of the bladder 82 as described above. The material capable of curing and hardening is allowed to cure and harden, providing a lining to the manhole 10 where the manhole liner 100 , the cured and hardened material, and the bladder 82 become an integral part of the manhole 10 . In embodiments where a chemical bond between the bladder 82 and the curable and/or hardenable material is desired, steam or heat may be introduced into the manhole 10 during the curing process to promote integration of the bladder 82 to the material capable of curing and/or hardening. Once the material is fully cured and/or hardened, areas of the lining that are unnecessary are cut away and removed from the manhole 10 .
It should be noted that FIG. 12 shows where the bladder 82 is placed into the manhole 10 by the use of an inversion process for the bladder 82 after the manhole liner 100 is attached to the casting frame 20 of the manhole 10 by the use of a flange member 68 . However, an inversion process is not required to practice this embodiment of the invention. Alternatively, the installation assembly as described in reference to FIG. 2 may be used to press the manhole liner 100 against the manhole walls. It should also be noted that all methods of the present invention should not be limited to the order of the recited steps. For instance, the manhole liner 100 may be impregnated with the material capable of curing and hardening before being placed into the manhole 10 . Alternatively, the material capable of curing and hardening may be placed onto the manhole walls, and the manhole liner 100 may be impregnated by the material capable of curing and hardening after insertion into the manhole 10 .
An alternative embodiment is illustrated in FIG. 13 . Here, the bladder 26 is inflated and expanded against the wall of the manhole 10 prior to applying a curable and/or hardenable material 42 . The curable and/or hardenable material 42 is applied to the interior surface 63 of the bladder 26 while the bladder is maintained under pressure and conforms to the wall of the manhole 10 . The curable and/or hardenable material 42 is then allowed to cure and harden, and portions of the bladder 26 are cut out and removed as previously described. In the illustrated embodiment, the sprayer is adapted to be an integral part of the installation assembly and the spray ribs 52 are movable along the post 36 between the lower rack 30 and the upper rack 22 .
This alternative embodiment has several advantages. The bladder 26 , preferably made of TPU with a wall thickness of 20-100 mils prior to expansion, provides a clean dry surface on which the curable and/or hardenable material is applied. The bladder also provides an impermeable barrier against the wall of the manhole that prevents ground water from washing away the curable and/or hardenable material and entering the manhole.
The invention has been shown and described above with the several embodiments, and it is understood that many modifications, substitutions, and additions may be made which are within the intended spirit and scope of the invention. From the foregoing, it can be seen that the present invention accomplishes at least all of its stated objectives. | The present invention comprises a method and kit for repairing the wall of a manhole wherein a material capable of curing and hardening is adhered to the wall. An expandable bladder engages the curable and hardenable material and presses against and smoothes the material. The bladder may be chemically bonded. | 4 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional Patent Application Serial No. 60/209,685, filed Jun. 6, 2000.
TECHNICAL FIELD
[0002] The invention relates generally to dispensing devices, and more particularly, to pouches containing a confectionery for use in the application of decorative confectionery for cakes and cookies, for example.
BACKGROUND OF THE INVENTION
[0003] Typically, flexible and collapsible dispensing bags of the type utilized for decorating cakes and cookies employ a dispensing bag having a relatively large filling opening at one end through which a flowable confection such as cake icing may be introduced. Typical dispensing bags include a relatively small dispensing opening at their other ends. Most prior art containers are substantially tapered from the filling to the discharge end with the lateral confines of the container being constituted of a flexible sheet material which may be formed of a plastic material, or a fabric impregnated with a synthetic resin.
[0004] The application of a confectionery to the top of and sides of an iced cake or other pastry is well known in the art. Typically, the confectionery is sufficiently viscous as to maintain its shape and is resistant to excessive flow or slumping after being dispensed from an associated bag. Some types of icing may tend to surface hardened by reason of water evaporation after being dispensed from the bag and, accordingly, it is desirable that pastry bags be substantially leak-proof to prevent hardening of its contents prior to application or leaking during application. Typically, white icings are shipped to retailers who, in turn, color the icing by adding food dye in a variety of different colors. Ordinarily, separate pastry bags are used for each color of icing.
[0005] It should be appreciated, such prior art dispensing systems require a baker or decorator to devote a considerable amount of time to mix appropriately colored icing, to fill and clean reusable pastry bags, and clean nozzle tips and other pastry bag accessories. In addition, the steps that need to be taken to dye, fill, and dispense icing from the number of different reusable icing bags results in additional undesirable side effects. For example, the steps of mixing, coloring, icing, and filling bags almost always results in some of the cake decorating material to be deposited at undesirable locations, such as the exterior of the bag, on the work table, and on the user's hands and garments.
SUMMARY OF THE INVENTION
[0006] It is a primary object of the present invention to provide a confectionery dispensing pouch that overcomes some of the aforementioned problems encountered by prior art devices.
[0007] Another object of the invention is to produce a pouch for dispensing confectionery which allows for improved control of the icing flow to increase artistic capability and sophistication. Still another object of the invention is to produce a confectionery dispensing pouch which provides the same advantages to the home user as the commercial baker.
[0008] Additional objects, advantages in other novel features of the invention will be set forth in the description that follows and will become apparent to those skilled in the art upon examination of the following detailed description of a preferred embodiment of the invention.
[0009] To achieve the foregoing and other objects, and in accordance with one aspect of the present invention, an improved prefilled confectionery dispensing pouch is provided.
[0010] The advantages and objectives of the invention may typically be achieved by a confectionery dispensing pouch which includes a flexible and collapsible container or pastry bag. Preferably, the container bag is formed of one or two sheets of tapered, flexible plastic material sealed together about the periphery to effect a leak-proof seal-of the contents contained therein. A nozzle is provided that is disposed between the narrower portions of the side walls of the dispensing bag and is preferably sealed to complete the leak-proof seal about the periphery of the flexible dispensing pouch. The nozzle preferably includes a number of external threads adapted to receive a retaining ring or decorating tip fitted with corresponding internal threads. A removable end cap is provided that is held in place by the retaining ring.
[0011] Still other objects of the present invention will become apparent to those skilled in this art from the following description and drawings wherein there is described and shown a preferred embodiment of this invention in the best mode contemplated for carrying out the invention. As will be realized, the invention is capable of other different embodiments and its several details are capable of modification in various, obvious aspects all without departing from the invention. Accordingly, the drawings and descriptions will be regarded as illustrative in nature and not as restrictive.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The above objects and advantages of the invention will become manifest to those skilled in the art from reading the following detailed description of a preferred embodiments of the invention when considered in the light of the accompanying drawings, in which:
[0013] [0013]FIG. 1 is a plan view of the dispensing pouch of an embodiment of the present invention;
[0014] [0014]FIG. 2 is a plan view of the dispensing pouch illustrated in FIG. 1 with a dispensing nozzle heat sealed in the outlet of the dispensing pouch;
[0015] [0015]FIG. 3 is an enlarged sectional view of the nozzle illustrated in FIG. 2 prior to the removal of the protective cover;
[0016] [0016]FIG. 4 is an enlarged sectional view of the nozzle illustrated in FIGS. 2 and 3 with a decorative dispensing tip;
[0017] [0017]FIG. 5 is an enlarged sectional view of the nozzle illustrated in FIGS. 2, 3, and 4 , showing the decorative dispensing tip removed and the protective cap in a resealed position;
[0018] [0018]FIG. 6 is an enlarged sectional view of a protective sealing cap arrangement;
[0019] [0019]FIG. 7 is a plan view with portions partially cut-away of an alternative dispensing pouch; and
[0020] [0020]FIG. 8 is a left hand side view of the dispensing pouch illustrated in FIG. 7.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0021] Reference will now be made in detail to the present preferred embodiment of the preferred embodiment of the invention, an example of which is illustrated in accompanying drawings, wherein like numerals indicate the same elements throughout the views. Referring now to the drawings, FIG. 1 shows the dispensing pouch of the present invention generally designated by the numeral 10 . The dispensing pouch is comprised of first and second side walls 11 . Each of the side walls 11 includes a top end and a relatively narrow bottom end. The side walls 11 are joined together along the marginal edges at 14 , preferably by heat sealing or other suitable means such as by the application of a suitable adhesive, by stitching or sewing or the like to form a flexible and collapsible container for flowable confectionery, for example. The flexible container is tapered and is of a generally triangular shape with an outlet opening 12 . Preferably, the flexible and collapsible icing container is comprised of a flexible sheet material which may be formed of a synthetic resin or plastic material. Other suitable materials include processed or treated fabric, such as fabric impregnated with a synthetic resin. Any materials that possess the sufficient flexibility and strength and are impervious to the contents to be dispensed would be appropriate for the side walls 11 of the dispensing pouch 10 of the invention.
[0022] It will be noted that the peripheral marginal edges 14 of the juxtaposed panels 11 are preferably heat sealed along the two parallel spaced apart edge portions and the top, leaving the outlet portion 12 open.
[0023] As clearly illustrated in FIG. 2, the dispensing pouch 10 of the present invention further includes a nozzle assembly 16 . The nozzle 16 includes an upper end that is disposed between and joined together with narrow bottom ends of the side walls 11 adjacent the outlet 12 . Preferably, the bottom ends of the side walls 11 are heat sealed (or sealed in another appropriate fashion) to the nozzle 16 , thereby effecting a leak-proof seal about the periphery of the outlet 12 . In such a manner, material stored within the dispensing pouch 10 may be stored and shipped with ease due to the stability of the material therein. The nozzle 16 is provided with a plurality of annular steps 18 which cooperate with the outlet portion 12 of the pouch 10 to produce a heat sealed relationship to occur between the side walls 11 and nozzle 16 . The nozzle 16 is also provided with an outer threaded portion 20 to receive the inner threaded portion of an annular retaining ring of collar 22 as illustrated in FIGS. 3, 4, and 5 .
[0024] A tamper evident tear seal tab 24 is provided on the outermost end of the nozzle 16 to assure the user that the dispensing pouch 10 has not been opened.
[0025] A removable end cap 26 is provided that is preferably substantially in the shape of a truncated cone and closed at its top. End cap 26 preferably fits on nozzle 16 in a snap-fit relationship and is secured thereto by a plastic driving hinge 28 . An internally threaded annular retaining ring 30 may be fit over end cap 26 and about nozzle 16 . By twisting the securing ring 22 , the internal threads thereof cooperate with threads 20 on the nozzle 16 . Such a configuration allows for the securing ring 22 to tightly and releasably secure end cap 26 in place during storage and transport of the prefilled dispensing pouch as illustrated in FIG. 3.
[0026] With reference to FIG. 4, there is shown a decorator tip 30 positioned on the nozzle 16 . The tip 30 is fastened to the nozzle 16 by the internally threaded collar 22 . When an alternative tip is desired, the collar 22 is initially removed by unthreading the same. Once completely loosened from the threads 20 of the nozzle 16 , the collar 22 is removed allowing removal and replacement of the tip 30 .
[0027] When it is desired to reseal the dispensing pouch assembly, the tip 30 is removed, the cover 26 is snapped into a resealing position, and the collar 22 is secured on the threads 20 as illustrated in FIG. 5.
[0028] [0028]FIG. 6 discloses another alternative resealing structure.
[0029] [0029]FIGS. 7 and 8 illustrate an alternative type dispensing pouch 10 ′ which may be satisfactorily substituted for the pouch 10 illustrated in FIGS. 1 and 2. More specifically, the dispensing pouch 10 ′ is comprised of first and second side walls 11 ′ which are substantially identical with one another. Each of the side walls 11 ′ includes a top end and a relatively narrow bottom end. The side walls 11 ′ are joined together, preferably along the marginal edges 14 ′, as illustrated in FIG. 7, preferably by heat sealing or other suitable means such as by stitching or sewing or the like to form a flexible and collapsible container for a flowable confectionery, for example. In the dispensing pouch 10 ′, another panel 40 of flexible material has the marginal edges thereof joined to the respective side panels 11 ′ along the respective marginal edges 14 ′ to form a flexible end of the completed pouch.
[0030] The flexible container or pouch 10 ′ is tapered and is of a generally triangular shape with an outlet opening 12 ′. Preferably, the pouch 10 ′ is formed of a flexible sheet material such as a synthetic resin or plastic material impervious to the contents to be dispensed.
[0031] The dispensing pouch 10 ′ is typically provided with a nozzle of the same type and applied in the same manner as in the embodiment illustrated in the other illustrations. The structural difference between the embodiments enables the embodiment illustrated in FIGS. 7 and 8 to be supported in a stand-up position on the end containing the panel 40 .
[0032] Unlike prior art dispensing bags, the dispensing pouch of the present invention allows icing to be pre-colored and disposed in the bag before it reaches the retail baker or other user. For example, a manufacturer may distribute a virtually limitless array and variety of colored icing by using the dispensing pouch of the present invention. By so doing, bakers or decorators would no longer be required to undertake the time-consuming and costly task of buying large amounts of white icing in bulk, mixing the icing, filling, using, and cleaning reusable pastry bags, nozzles, etc. The dispensing pouch of the present invention will enable a user to purchase only the colors and amount of icing needed.
[0033] In FIGS. 2, 3, and 4 of the invention, the tip 30 and the sealing cap 26 are shown as being secured to the nozzle 16 by an internally threaded retainer ring 22 . It will be appreciated that equally viable would be structures wherein the tips or the sealing caps are provided with self-contained threads negating the requirement for a separate attachment ring.
[0034] From the above description, it will be appreciated that the present invention may be utilized as a retail package for sale to and used by the homemaker, as well as the bakery department in a retail store or a commercial bakery.
[0035] The foregoing description of the preferred embodiment has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed. Obvious modifications or variations are possible in light of the above teachings. The embodiment was chosen and described in order to best illustrate the principles of the present invention and its practical application to thereby enable one of ordinary skill in the art to best utilize the invention and the various embodiments and with various modifications as are suited to the particular use contemplated.
[0036] In accordance with the provisions of the patent statutes, the present invention has been described in what is considered to represent its preferred embodiment. However, it should be understood that the invention can be practiced otherwise than as specifically illustrated and described without departing from its spirit or scope. | An improved dispensing pouch is provided having a flexible and collapsible container consisting of a pair of tapered side walls ( 14 ). A nozzle ( 12 ) is disposed at the lower end of the flexible container and heat sealed thereto. A removable end cap ( 26 ) is preferably snap-fit on to the nozzle and held in place by a retainer ring ( 30 ) or a nozzle with integral scaling threads ( 20 ). The side walls of the icing container are preferably heat sealed about the perimeter and on to the nozzle to effect a leak-proof container for the contents contained within. | 1 |
FIELD OF THE INVENTION
This invention relates to washing machines. More particularly but not exclusively, the invention relates to machines for washing dust mats made of cotton or nylon with a rubber, latex or nitrile backing.
PRIOR ART
In British Patent Specification No. 1493680 there is described a washing machine suitable for washing a washable dust mat which includes means for supplying a washing liquid to each mat in turn from a tank, and means for collecting the used washing liquid and returning the collected washing liquid to the tank whereupon it may be reused. Each mat is subsequently rinsed with a fresh supply of rinsing water, but the excess rinsing water is also collected and fed to the tank from which each cycle of washing liquid is supplied. Thus instead of using a fresh supply of washing liquid for washing each mat, the washing liquid used for one mat is collected in the tank together with the excess rinsing water and then the washing liquid for the next mat is withdrawn from the tank. The overall amount of water used and the amount of heat, e.g. steam, required compared with machines which use a fresh supply of water for each washing cycle, is considerably reduced. A proportion of the used washing liquid is continuously being drained from the tank, the amount of liquid being drained being equal to the amount of rinsing water being collected minus the amount of water retained by the mats.
It is well known to provide the washing machine with filtration apparatus so that heavily soiled mats may be washed without the used washing liquid in the tank becoming unacceptably dirty for further use, too quickly. Such filtration apparatus is described in the specification of British Patent Application No. 25692/76.
SUMMARY
According to the invention a washing machine suitable for washing a washable dust mat comprises means for supplying a main wash liquid to each mat in turn from a tank, means for collecting at least the used main wash liquid and returning it to the tank, an overflow from the tank, means for employing the overflow of liquid from the tank in a pre-washing operation for each mat, and means for rinsing the washed mat.
The pre-washing operation will remove a proportion of the dirt and particles from the mats and thereby help to stop the washing liquid in the tank from becoming unacceptably dirty, too quickly.
Preferably said means for employing liquid from the tank in a pre-washing operation comprises a second tank connected to said overflow from the first-mentioned tank, means for supplying the liquid from the second tank as a pre-wash liquid to each mat in turn, means for collecting the used pre-wash liquid and returning it to the second tank, and an overflow from the second tank connected to drain.
It is also preferred that each mat is rinsed with a fresh supply of rinsing water, the used rinsing water being collected in the first tank.
Preferably the washing machine includes arcuate guide means, e.g. a drum, around at least a part of whose circumference each mat is passed during its successive pre-wash, main wash and rinsing operations. In one embodiment of the invention at least one row of jets is provided for applying each of the main wash and pre-wash liquids, the pre-wash jets being upstream of the main wash jets, and both said jets being arranged to eject the respective liquid radially of the drum and at an angle to the vertical.
The means for collecting the used main wash liquid preferably include apparatus for filtering the liquid before it is returned to the respective tank. Also if means are provided for collecting the pre-wash liquid and returning it to a second tank, then such means preferably include filtration apparatus. The or each filtration apparatus preferably comprises means for screen filtering the respective liquid and also means for filtering the respective liquid by precipitation.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an elevation, by way of example, of the washing and rinsing sections of a washing machine for washable dust mats;
FIG. 2 is a perspective view of the water recycling tanks of the washing machine of FIG. 1; and
FIG. 3 is a plan view of the recycling tanks and the filtration apparatus of the washing machine of FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENT
This example is concerned with a machine for washing a succession of washable dust mats, which is similar to the washing machine shown in FIGS. 6 and 7 of British Patent Specification No. 1493680.
Referring to FIG. 1, the washing machine has a central, rotating drum 10 with two rows of main wash jets 11, 12, a supply pipe 13 for clean rinsing water, three squeeze rollers 14, 15 and 22, and a main pressure roller 16 disposed adjacent the peripheral surface of the drum 10. The drum is driven by a motor 27 in a clockwise direction as viewed in FIG. 1, and pneumatic jacks 42 to 44 are provided to cause the squeeze rollers 14, 15 and 22 respectively to effect a squeezing action on each mat 40. A further pneumatic jack 45 and linkage 80 is provided to actuate the pressure roller 16.
In the washing machine described in the aforesaid patent specification the equivalent wash jets are disposed at substantially the same level as the axis of the drum 10. However, in this embodiment, the main wash jets 11, 12 are at a lower position within the lower left-hand quartile as viewed in FIG. 1, and spaced apart on either side of the first squeeze roller 22 in the direction of movement of the mats. The jets 11, 12 are also arranged to eject the main wash liquid both radially of the drum and at a sufficient angle to the vertical to preclude the washing liquid falling back off the mats 40, which are substantially upside down at this point, onto the jets.
The mats 40 are carried around the drum by first, second and third carriers 17, 18, and 29 each of which comprises a series of cords or belts 19 spaced apart axially of the drum and driven either directly by the drum or by the mat passing between the drum and the respective belts. The belts of the first carrier 17 pass around the first squeeze roller 22 and four spindles 21, 23, 28 and 81 of which the spindle 81 has its ends mounted in slides for tensioning the belts after they have been joined.
In the case of the second carrier 18, the belts 19 pass around the spindle 23, the squeeze rollers 14 and 22 and a tensioning spindle 30. The belts of the third carrier 29 pass around the squeeze rollers 14, 15, a spindle 31 disposed intermediate the third squeeze roller 15 and the pressure roller 16, and a tensioning spindle 32. The spindle 31 is freely mounted within a wedge-like space created between the surface of the drum 10 and a plate 33 disposed at an angle of about 15° to the vertical, the spindle being kept in the space by the tension of the belts of the third carrier. If desired, the belts of the second and third carriers 18, 29 may be passed around a common tensioning roller.
The spaced apart belts 19 of the first and second carriers 17, 18 allow the main wash liquid to be applied to the mat being washed between the belts. Also, the belts of the two carriers are not aligned in the direction of movement of the mats so that no portion of the mat is hidden from both rows of main wash jets 11, 12.
Upstream of the main wash jets 11, 12 and disposed in the lower, right-hand quartile of the drum as viewed in FIG. 1, is a row of pre-wash jets 24 which like each row of the main wash jets 11, 12 are directed radially at the drum at a sufficient angle to the vertical to avoid the pre-wash liquid falling back off the mat 40 being washed on to the jets 24.
To feed each mat in turn to the first carrier 17 there is provided a further belt conveyor 34 whose belts pass around a spindle 20 and the above-mentioned spindle 21 of the first carrier, the belts of the conveyor 34 passing around a smaller radius on the spindle 21 than the belts 19 of the first carrier so that they travel at a slower speed than the belts 19 of the first carrier.
Also, in this embodiment, downstream of the pressure roller 16, there is a brush roller 41, which is driven in an anticlockwise direction as viewed in FIG. 1 by drive means from the pressure roller 16 at a faster speed than the pressure roller, to fluff up the pile of the mats after they have been washed and rinsed and to act as a stripper should the mats tend to cling to the pressure roller 16. The roller 41 is mounted so that its position is adjustable radially of the drum. In other embodiments, instead of or in addition to the brush roller 41 there is provided an impregnating roller for applying a finishing oil to the mats.
It will be appreciated that in operation of the apparatus described so far, each mat to be washed is successively pre-washed by a pre-wash liquid applied to the mat by the pre-wash jets 24, washed by a main wash liquid applied by the main wash jets 11, 12, and rinsed by water from the pipe 13. The first and second squeeze rollers 22, 14 act to remove a proportion of the main wash liquid from the mat. The rinsing operation takes place in two stages, the cleaner water from the pool 74 of the second rinsing stage passing through grooves in the third squeeze roller 15 provided for the belts of the third carrier 29 to form the pool 35 of the first rinsing stage. The used main wash liquid and the used rinsing water removed from the mats by all three squeeze rollers 14, 15 and 22 and the pressure roller 16 is collected by a funnel 25 and directed into a first catchment tray 26 extending longitudinally of the roller 10. Similarly, the used pre-wash liquid is collected by a funnel 36 which is separated from the funnel 25 by a screen 37 and directed into a second catchment tray 38.
The apparatus provided for recycling the major proportion of the collected liquid for supplying the main wash jets 11, 12 and the pre-wash jets 24 will now be described. With reference to FIGS. 2 and 3, liquid collected by the first catchment tray 26 passes into a channel 75 provided with transverse baffles 39 which assist the precipitation of dirt and particles from the liquid. The liquid then passes into a screen filtration channel 42 having a curved perforated base 43 to separate out loose fibres and other floating matter from the liquid which are swept from the channel into a receptacle 44 by a rotary double-ended brush 45 mounted on a spindle 70 which is driven by a motor 71, through a drive belt 72. The filtered liquid passes through the base 43 of the channel 42 onto a chute 49 leading to a tank 46 which is the supply tank for the main wash liquid and which is connected to both rows of main wash jets 11, 12 by pipework 47 including a pump 48. A feed pipe 82 is provided for dispensing detergent into the tank 46 at an appropriate rate. Also to extend the path of the liquid within the tank in order that even more dirt and particles will precipitate out, the tank has a longitudinal dividing wall 79 with a communicating aperture 50. The liquid is reheated by steam from a pipe 51 located in the downstream part 52 of the tank 46. An overflow 53 is provided at the end of the upstream part 54 of the tank which is remote from the chute 49 for the removal of floating effluent and suds. The overflow 53 leads to a receptacle 55 having an outlet 56 to drain. The base of each part 52, 54 of the tank 46 also has an outlet 57 to drain which is normally closed but which may be opened to allow the tank to be cleaned.
The used pre-wash liquid collected by the second catchment tray 38 is also passed through a precipitation channel 58 and a screen filtration channel 59 before entering the upstream part 78 of a second tank 60. The part 78 has a communication aperture 61 with the downstream part 62 of the tank 60 which is connected to the pre-wash jets 24 by pipework 63 including a pump 64. In the case of this second tank 60, the upstream part 38 has an overflow 65 for the suds and other floating matter and the downstream part has a lower overflow 66 for excess liquid, both overflows passing into the same receptacle 55 as the overflow 53 of the tank 46. At the same time there is provided an overflow connection 67 between the upstream parts 52, 78 of the two tanks 46, 60 whereby there is a constant feed of liquid from the tank 46 into the tank 60. The liquid in the second tank 60 is reheated by steam from a pipe 68.
In practice it is intended that the amount of liquid passing out of the second tank 60 by the overflow 66 should equal the amount of rinsing water used less the amount of water retained by the mats. The drain outlet 56 of the overflow receptacle 55 although normally open is provided with a valve 69 to allow the outlet 56 to be closed should the washing machine have to be stopped. Closure of the valve 69 may be used to maintain the tanks 46, 60 at a priming level and thereby avoid both the wastage of liquid to drain and the necessity to refill the tanks to the required levels before the washing machine can be restarted.
It will thus be appreciated that in the embodiment described above a proportion of the main wash liquid and rinsing water, which would otherwise be passed to drain, is used to perform a pre-wash operation on the mats. This pre-wash operation serves to remove some of the dirt and particles in each mat before the main washing operation thereon. More importantly, it reduces the amount of dirt and particles which would otherwise be removed during the main wash operation and thus results in the liquid in the tank 46 remaining sufficiently clean for recirculation to the main wash jets 11, 12 over a longer washing period than would otherwise be the case. | A washing machine suitable for washing a washable dust mat comprises means for supplying a main wash liquid to each mat in turn from a tank, means for collecting at least the used main wash liquid and returning it to the tank, an overflow from the tank, means for employing the overflow of liquid from the tank in a pre-washing operation for each mat, and means for rinsing the washed mat. A single supply of water is thereby recirculated to provide the main wash liquid and also provides the pre-wash liquid. | 3 |
BACKGROUND OF THE INVENTION
[0001] 1. Field Of The Invention
[0002] The invention was developed to apply substances such as Armor-All to such things as car tires when detailing the cars. Although the invention is not limited to this application, it is its primary focus.
[0003] 2. Problems In The Art
[0004] The conventional way to apply such things as Armor-All is to either squirt it out of a standard manually pumped spray bottle (for example a Winde™ bottle) or to pour some of the fluid on a cloth or rag and swipe it on the surface to which it is to be applied. Even with the spray bottle, a cloth or rag is needed to wipe and smooth it out over the surface. There are times when the liquid needs to be penetrate somewhat into the surface of application, and mere wiping is insufficient.
[0005] A third method involves use of a sponge-type applicator such as liquid shoe polish or the like. It still usually requires some wiping or working with cloth. Foam applicators are sometimes used, but they deteriorate quite rapidly due to the rough surfaces of tires, and the lettering found on many tires.
[0006] The problems with these techniques is that they generally require the two-step process of dispensing the fluid from its container and then wiping it on or working it into the surface. They also create a subtle but significant problem of having the substance on rags or applicators which in turn then causes the user's hands to come into contact with the substance. It also results in spillage of the substance.
[0007] The problem with the above is that if the user's hands come in contact or the rags or towels come in contact with the liquid, it is difficult to clean and can drip or be transferred to floors and make them slippery. It can also be damaging to the user's skin. Some of these substances are dangerous if exposure to eyes or skin occur, or if inhaled through the nose or ingested into the lungs.
[0008] Further, the above application methods tend to utilize a lot of the substance (more than is needed for the surface) and therefore a significant amount of liquid and thus a significant amount of cost is involved in the application of the substance.
[0009] There are a variety of different types of vinyl and rubber protectorant fluids. Examples are Armor-All™ Protectorant of Armor-All™ Products Corporation of Aliso Viejo, Calif.; ReTire from Zep Products, of Smyrna, Ga.; and Ultra Shine Tire Protectorant from Grace-Lee Products, of Minneapolis, Minn. Most of them are packaged in relatively small hand-held sized plastic bottles. Some of the containers simply have screw off caps. The substance is poured onto a rag or other applicator. The substance is then wiped and/or worked onto a targeted surface, such as, for example, a car tire or other vinyl or rubber parts of an automobile. Using this process, it is very hard to regulate the amount of fluid that is dispensed out of the bottle that should be commenced with the needs of the targeted surface. In other words, the user just estimates how much to pour onto the applicator. Because most applicators are absorbent, any excess is either inefficiently placed on the target surface, or retained in the absorbent applicator. However, in both cases many times too much of the fluid is dispensed.
[0010] Furthermore, the steps of pouring fluid onto an applicator, then moving the applicator to a surface, and then wiping the applicator on the surface all involve possible spillage. Also, the applicator either has a limited life span, or must be cleaned from time to time. If a rag, this means it must be washed, for example in a washing machine. The types of liquid protectorants discussed, are not necessarily environmentally friendly. Therefore, if the substance is able to be removed from the cloth or towel, it then enters the water and is placed into the water system of the municipality. Otherwise, the applicator must be washed under a hose or other facilities and again the substance would enter the municipal water system or fall or run off to the ground and also could enter ground water. Such substances are also potentially hazardous because if spilled on the floor, they can create slippery areas. Workers or customers would be exposed to this risk. The substances may produce environmentally hazardous substances when decomposing.
[0011] Other conventional types of containers for such fluids may incorporate in the hand-held bottle a spray nozzle with a manually pumped delivery system. Dispension of the fluid is therefore arguably easier, as is control over dispension of the fluid. However, the spray is generally not fine in nature. The amount of control is also not precise. This results in either an inefficient amount of the substance being applied to the surface, or spillage, splattering, dripping, or mis-direction of the spray; again resulting in waste of the fluid as well as creating possible negative environmental consequences. Moreover, even using the spray dispensers requires the second step of then wiping the substance over the targeted surface. Similar problems regarding use of such an applicator therefore occur.
[0012] It should also be mentioned that most hand-held sized containers hold a relatively small amount of the fluid. This is especially inefficient for businesses that use a relatively large amount of the fluid over the course of a day. It requires a change-over of containers frequently as well as the uneconomic of paying for a large number of containers. Thus, the convenience of having a small hand-sized container, including the maneuverability of the same, is countervailed by the small amount of fluid that it can contain as well as the problems with imprecise amounts of fluid used and spillage.
OBJECTIVES OF THE INVENTION
[0013] The primary object of the invention is to improve upon the problems and deficiencies in the art. For example, improvement is needed in eliminating the wiping step with towels, rags, or sponges. Also it would be very beneficial to eliminate any human contact with the substance. It is important to decrease the amount of substance used.
[0014] It is therefore a principal object of the present invention to provide a method and apparatus which solve or improve over the problems and deficiencies in the art.
[0015] Further objects, features, and advantages of the present invention include a method and apparatus which:
[0016] a. Allow more precise control placement of the fluid on a targeted surface in an appropriate amount.
[0017] b. Allow better dispension of fluid from a holding container.
[0018] c. Reduce spillage, drips, or inaccurate placement of the fluid.
[0019] d. Deter potential hazards of spillage of the fluid on the working area, which can render it slippery, or to the user.
[0020] e. Deter and reduce adverse environmental effects of the fluid.
[0021] f. Provides a substantial amount of fluid in a portable manner readily available for delivery to an applicator.
[0022] g. Are durable.
[0023] h. Are re-fillable.
[0024] i. Are easily repairable and maintained.
[0025] j. Are efficient and economical.
[0026] k. Are easily handled and maneuvered manually by a worker and do not constrain free movement around a vehicle or targeted surface.
[0027] These and other objects, features, and advantages of the present invention will become more apparent with reference to the accompanying specification and claims.
SUMMARY OF THE INVENTION
[0028] The present invention relates to an apparatus and method for applying liquid protectorant to a targeted surface. The apparatus consists of a container for holding a supply of liquid protectorant. A hand-held applicator is in fluid communication with the container through a conduit. A controller, which can meter the amount of fluid passing from the container to the applicator, is operatively connected to the apparatus. The applicator includes an application head. A nozzle is surrounded by the application head but has sufficient excess space around the nozzle so that fluid can be sprayed substantially directly to the targeted surface but is constrained from traveling to places other than the target surface when the applicator is placed on or near the targeted surface.
[0029] The container applicator and conduit are operable by hand and portable. Thus, in one step via a delivery system, the fluid in the container is dispensed and delivered to the applicator nozzle. When the applicator is placed on the targeted surface, the fluid can be directed only to the surface and in quantities controllable by the controller. The applicator can at the same time wipe, spread or work the dispensed fluid across and/or into the targeted surface while maintaining the fluid on the targeted surface.
[0030] The method according to the invention includes containing a relatively large supply of liquid protectorant in a manner that is hand portable, conveying the liquid in a controlled matter to a targeted surface while surrounding the dispensing of the fluid to prevent spillage or direction of the fluid outside the targeted surface and spreading the dispensed liquid across the targeted surface.
BRIEF DESCRIPTION OF THE DRAWINGS
[0031] [0031]FIG. 1 is a perspective view of a preferred embodiment of the invention, including a partial perspective view of an automobile tire and illustrating the hand-held nature of the apparatus.
[0032] [0032]FIG. 2 is an enlarged perspective view of the preferred embodiment of FIG. 1.
[0033] [0033]FIG. 3 is an still further enlarged sectional view taken along line 3 - 3 of FIG. 2.
[0034] [0034]FIG. 4 is a bottom plan view of FIG. 3.
[0035] [0035]FIG. 5 is an enlarged isolated perspective taken along line 5 - 5 of FIG. 3.
[0036] [0036]FIG. 6 is an enlarged sectional view taken along line 6 - 6 of FIG. 5.
[0037] [0037]FIG. 7 is an sectional view taken along line 7 - 7 of FIG. 6.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0038] In order to provide a better understanding of the invention, one embodiment of the invention will now be described in detail. Frequent reference will be taken to the drawings. Reference numbers will be used to indicate certain parts and locations in the drawings. The same reference numbers will be used to indicate the same parts and locations throughout the drawings unless otherwise indicated.
[0039] It is to be understood that the preferred embodiment is but one form and configuration the invention can take. This detailed description is neither intended nor does it limit the invention, which is solely defined by claims set forth herein.
[0040] The basic structure and environment of the invention will first be described, followed by more detail of the structure of the preferred embodiment of the invention, followed by a description of the operation of the preferred embodiment, and finally, concluded with a discussion of exemplary options, features, and alternatives with regard to the invention.
[0041] By referring to FIG. 1, an automobile 8 is illustrated along with an associated tire sidewall 9 . Automobile detailing businesses sometimes utilize vinyl or rubber protectorant fluid to clean, protect, and improve the aesthetic appearance of automobile tires. Businesses involved in the same therefore utilize substantial quantities of the protectorant.
[0042] [0042]FIG. 1 shows a preferred embodiment of the invention. The device 10 includes a brush applicator (indicated generally at reference number 12 ) connected via hose 14 to a pressurized, hand-held canister 16 . The substance to be dispensed (e.g. Armor-All™) is in pressurized canister 16 .
[0043] The liquid protectorant is generically described as a vinyl and rubber protectorant fluid. Such fluids are well known in the art. The specific composition of such fluids is not pertinent to the invention other than the fact that when spilled on the floor they can be slippery and that they are not necessarily environmentally or user friendly. FIG. 1 illustrates that the user can grip applicator 12 by hand (see reference number 15 ) and manipulate brush applicator 12 relative to tire sidewall 9 in an easy and efficient manner.
[0044] The brush applicator 12 is comprised of a head 18 , bristles 20 extending from head 18 , a handle (generally indicated at 22 ) that comprises a hollow conduit, a valve 24 along conduit 22 and an exterior gripping portion 28 . A hand lever 26 operates valve 24 . By pushing lever 26 towards conduit 22 , valve 24 increasingly opens and provides a fluid conduit pathway from hose 14 to head 18 . Then lever 26 is in this normal, undepressed position, the fluid pathway through valve 24 is blocked or closed.
[0045] Canister 16 includes a main body 30 , coupling 32 for hose 14 , a hand grip 34 , a {fraction (15/16)}″ hex release valve/filling cap 36 , and an air filling valve/cap 38 . Protectorant can be placed into canister 16 by removing cap 36 . The interior of canister 16 can be pressurized by removing cap 38 (when cap 36 is in place on canister 16 ) and adding pressurized air through 38 . Pressure can be adjusted or released through valve 36 . Caps 36 and 38 are threadably attached in place.
[0046] [0046]FIG. 2 shows in apparatus 10 in enlarged detail.
[0047] [0047]FIGS. 3 and 4 illustrate that a conduit 42 is formed in and extends through head 18 into a nozzle 40 from conduit 22 . Nozzle 40 is basically centered in the middle of bristles 20 and extends at least approximately halfway from head 18 through bristles 40 . It is furthermore noted that nozzle 40 has a very small aperture 44 through which the fluid can be disbursed.
[0048] It is further important to note that there is intentionally an open area 45 around nozzle 40 (extending from the bottom of head 18 to the distal ends of bristles 20 ). Dashed line 46 is used to indicate that open area where no bristles 20 exist.
[0049] Head 18 can be made of plastic material. One end of conduit 42 would comprise threaded aperture 50 which receives the threaded male end 52 of connector 54 , which in turn can receive a male threaded end 56 of handle 22 into a threaded aperture therein. It should be noted that the fittings comprising 52 , 54 , and 56 can be made of metal, for example brass or other corrosion resistant metals. Furthermore, to provide a sealing action against leakage, Teflon tape can be utilized between threaded parts, such as known in the art. An alternative is nitrile tape. Use of such materials is beneficial because rubber seals such as (rubber O-rings), could be corroded by the liquid protectorant.
[0050] Nozzle 40 has a male threaded into 58 that fits within the female thread of aperture 60 at the other end of conduit 42 in head 18 . As can be seen further in FIG. 6, nozzle tip 62 in turn can be threaded via its male threaded end 64 into the other part of nozzle 40 indicated at reference number 66 .
[0051] As illustrated by lines 67 , nozzle 40 functions to mist or spray liquid protectorant delivered through conduit 42 in a manner that would exit open area 45 . Bristles 20 would essentially surround, by 360°, nozzle 40 and therefore fluid could not pass through bristles 20 and thus is constrained to pass out of opening 45 or strike the innermost bristles 20 relative to nozzle 40 .
[0052] FIGS. 5 - 7 illustrated in detail of the structure of nozzle 40 . It is pointed out that nozzle 40 is easily replaceable and removable for maintenance and cleaning. It is also removeable to interchange nozzle size and for spray characteristics. By referring particular FIG. 6, it can be shown that portion 66 of nozzle 40 includes a bore 68 having an upper open end 70 . Bore 68 increases somewhat in diameter at its lower portion (see reference numeral 72 ). In portion 72 of bore 68 is a screen 74 that is annular is shape and covers the bottom end of bore 68 .
[0053] As can be seen in FIG. 6, the very tip 76 of nozzle 40 has a bore 78 longitudinally therethrough with an upper end 80 in fluid communication with bore 68 . An insert 82 is threaded into tip 76 . Dashed lines 84 and 85 illustrate the flow path of fluid through insert 82 . The fluid is allowed to travel longitudinally along nozzle 40 until the location indicated at 86 which blocks further axial movement. Fluid has to travel around sides of part 86 (see annular void 88 in FIG. 7, and then enter channel 90 where it flows out increasingly constricted pinhole 92 .
[0054] The detailed structure of nozzle 40 is discussed for the following reason. By utilizing such a nozzle, the fluid first must pass in pressurized fashion through screen 74 . This filters out any solid particulars and serves to break up the fluid. The fluid is then forced through increasingly smaller passage ways until it finally must travel around part 86 and through very small channel 90 and then out an increasingly constricted pinhole 92 . The cooperation of these elements therefore causes good aeration and essentially atomizing or misting as it leaves pinhole 92 . By doing so, economy in the use of the fluid is achieved along with the efficiency of use of fluid.
[0055] Operation of device 10 is shown by referring to the Figures and is as follows. The combination of FIG. 1 is assembled. The fluid to be dispensed is placed into canister 16 by filling cap 36 . Cap 36 is sealingly replaced, cap 38 is removed, and canister 16 is pressurized or charged through conventional valve 38 (with valve core)(through a standard air chuck operatively connected to the air stem valve 38 via a bicycle pump or other pressurized air source). Valve 38 is identical to an air valve on a bicycle tire. Nozzle 40 has been pre-designed to extend downwardly the distance relative to the length of bristles 20 . It is noted that a benefit of this is that if the user presses bristles 20 too hard on a surface, the distal end of nozzle 40 would prevent complete bending and possible deformation or damage to bristles 20 or when bristles rebound, deters splattering.
[0056] The head 18 has been designed so that bristles 20 are approximately 2½ inches in length. They are intentionally selected to be of the type that have a soft edge that tends to absorb some of the product like a sponge.
[0057] Nozzle 40 extends approximately 1¼ inch down through bristles 20 . The unobstructed area 45 around nozzle 40 is approximately 1 to 1½ inches wide. The remainder of the bristles 20 occupy the remainder of the approximately 4½ inch diameter of brush head 18 .
[0058] Nozzle opening 44 is very small, almost pinhole size. Examples are #2 (0.025″ diam.) and #4 (0.050″ diam.) nozzle sizes; #2 for lighter fluids and #4 for heavier fluids. It is preferred that liquid lighter than No. 10 motor oil be used with device 10 . If the liquid is too heavy, more of a pinstream than a mist is produced. Therefore, if the liquid is too heavy, one might dilute it or use a slightly larger hole size for nozzle opening 44 (e.g. #2 for lighter fluids and #4 for heavier fluids).
[0059] Canister 16 is pressurized to maximum pressure of 200 psi. The maximum liquid capacity is 32 ounces. It has been found that 40 psi is about the minimum pressurization for good operability.
[0060] The combination of the pressurization of the fluid and the pinhole opening 44 results in a mist-like or almost vaporized discharge of the fluid through nozzle 40 . The unobstructed space around nozzle 40 allows the misted fluid to get to the surface and then the brush bristles are used to spread it out evenly thereover.
[0061] As seen in FIG. 1, canister 16 handled 34 can be gripped with one hand of the user and applicator 12 with the other hand of the user. The user can then efficiently walk to automobile 8 and tire sidewall 9 and easily place the brush bristles 20 directly to sidewall 9 . The bristles should be gently placed on sidewall 9 , preferably at the middle of one side of the tire.
[0062] Lever 26 can be depressed and released to discharge the misted fluid for short bursts and then released to allow the brush to apply it to the surface. The fluid should be applied sparingly and the brush gently moved clockwise following the outer edge of the rim of the tire until a 360° pass has been made. Then the brush is moved counter-clockwise around the outer edge of the sidewall for another 360°. If needed, several other short pulls of the trigger can be made to provide a little more fluid. The whole tire is covered with two passes. Starting and finishing at the middle prevents drips on the floor or on the tire.
[0063] Once the protectorant fluid is dispensed onto a portion of sidewall 9 , while bristles 20 protect against any liquid going to an area other than the targeted part of sidewall 9 , the user can quickly and easily wipe or brush 20 around sidewall 9 . The brush allows the liquid to be worked into the targeted surface. Short bursts of trigger 26 can be made according to need and experience to dispense appropriate amounts of liquid protectorant on sidewall 9 and simultaneously wipe and work the protectorant comprehensively around the sidewall 9 . Once entire sidewall 9 has been treated, the user can easily move apparatus 10 to the next tire or location.
[0064] It will be appreciated the present invention can take many forms and embodiments. The true incense and spirit of this invention are defined in the impended claims, and it is not intended that the embodiment of the invention presented here and should limit the scope thereof. Variations obvious to one skill in the art will be included with the invention, within the invention defined by the claims.
[0065] For example, the type of nozzle can vary according to need and desire. In the preferred embodiment, the nozzle mists or atomizes or vaporizes the fluid. In certain circumstances, more volume and less misting of the fluid may be desirable.
[0066] The exact position of the nozzle 40 relative to the brush bristles, including open area 45 in relationship of the distal end of nozzle 40 relative to the applicator head 18 and the distal head end of bristles 20 , can be varied according to need. Bristles 20 can, for example, be flag-brush. They can have a fine but soft edge and have some absorbent qualities.
[0067] Container 30 can be a metal canister, preferably stainless steel. It specific size can be varied according to need and desire, but it is preferred that it be easily portable by gripping and moving in a hand-held manner. Different delivery systems could be used including aerosol or by attachment to a central pressurized distribution system.
[0068] The grip 28 for handle 22 can be ½″ rubber hose or a formed handle grip. It is preferred that handle 22 be relatively short to allow for greater flexibility and maneuverability of head 18 relative to targeted areas. Conduit 14 is preferred to be flexible but made of an material that resists corrosion by material such as those used with the invention. An example such hoses are those that are used to apply acidic fluids.
[0069] Alternatively to canister 16 , a larger container or a pressurized air source could be used to push the product through the brush. It is even possible to attach a plurality of brush applicators 12 by a plurality of hoses 14 to a centralized source of pressurized fluid. Hose 14 can be short or long. Examples are 5′, 10′ and 25′.
[0070] The valve 24 is placed near the brush applicator 12 instead of at the canister 16 to eliminate any run-on of pressurized fluid if the valve was at canister 16 and turned off. In other words, having the valve at or near brush applicator 12 allows quicker on/off of fluid discharge and therefore less waste of material.
[0071] Therefore, the device can apply a precisely controllable, economical amount of the fluid, and allow it to be spread evenly and thoroughly, without any need for contacting the user or being placed on any intermediate applicator, such as a cloth. The mist is contained within the open area of the brush bristles so as not to be wasted on other than the surface intended, furthermore allowing a more economical and efficient application of the substance.
[0072] It has been the experience of the inventor that an up to 80% savings in the amount of fluid to be used (in this example Armor-All™) can be realized. This translates in substantial economic savings.
[0073] By way of another example, it is the experience of the inventor that in traditional methods, 4 ounces of liquid protectorant are used per car (all four tires). But with the present invention this amount has been reduced to approximately ½ ounce per car. Considering that an automobile detailing company might go through over 50 gallons of liquid protectorant in a week, the amount of savings cumulatively is substantial. Also, expense, time and labor of washing rags or applicators is eliminated or reduced, cleaning up spills, and damaging environment, users, or non-targeting areas is reduced. | An apparatus and method for applying liquid protectorant to a targeted surface, such as a automobile tire sidewall, comprising a container for holding the liquid protectorant, a hand-held applicator, and a conduit between the container and the applicator. And one embodiment, the container is pressurized and a manually controllable valve is operable to deliver the liquid protectorant from the container to the applicator. The applicator includes a nozzle for delivering liquid protectorant. The nozzle, however, is surrounded by portions of the applicator, for example brush bristles, to prevent liquid protectorant from traveling to other than the targeted area. | 0 |
This is a division of application Ser. No. 211,601, filed June 27, 1988, now U.S. Pat. No. 4,885,935.
BACKGROUND OF THE INVENTION
1. Technical Field
This invention relates to an engine testing system.
2. Background Art
After fabrication of an engine, it is typically desirable to test the engine to insure correct operation. This often presents difficulties which are not present when the engine is installed in the car. For example, certain sensors needed for engine operation may not yet have been installed. Of course, all missing sensors could be temporarily installed and the engine tested on an engine dynamometer installation. However, such an installation is relatively expensive to maintain, each engine test may take a relatively long time, and the test results are dependent upon sensors which are present only during the test and are not the same ones later installed on the engine. When many engines are being produced, the total time and cost of testing the engines may be substantial.
It would be advantageous to have an engine control system suitable for testing an engine at the end of a production line which is accurate, has reduced cost, and avoids the need for pressure sensors, airflow meters and complex control modules. These are some of the problems this invention overcomes.
SUMMARY OF THE INVENTION
An engine testing system in accordance with an embodiment of this invention has an air charge determination means which generates an indication of engine air charge. The engine testing system further includes a table defining an engine operating parameter as a function of both engine speed and adaptive engine air charge. For example, such a table can be a spark table defining engine ignition spark timing as a function of both engine air charge and engine speed or a fuel multiplier table defining a fuel charge adjustment applied to the engine as a function of both normalized throttle angle and engine coolant temperature Advantageously, for each table, air charge is defined by throttle angle. Thus an engine testing sYstem in accordance with an embodiment of this invention can provide interactive, adaptive control for spark timing, fuel injection, and idle speed control using throttle angle and engine speed as primary inputs.
As a result, end of line engine testing can be accomplished without the need for mass airflow sensors or manifold absolute pressure sensors. Such engine testing using interactive control of engine operation with adaptive throttle angle and engine speed as primary inputs is available at a relatively low cost. The low cost advantage is obtained, in part, because of the capability for inferring air charge through the measurement of throttle position and avoiding the use of a manifold absolute pressure sensor Advantageously, the engine testing system does make use of a throttle position sensor, an engine coolant sensor, an idle speed control valve, an ignition system, fuel injectors, a fuel rail and an engine wiring harness.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of an engine testing system in accordance with an embodiment of this invention;
FIG. 2 is a block diagram of a control module portion of FIG. 1, in accordance with an embodiment of this invention;
FIG. 3A is a table representing engine air charge with respect to normalized throttle angle and engine speed;
FIG. 3B is a table representing spark advance with respect to engine air charge and engine speed;
FIG. 3C is a table representing the magnitude of a fuel adjustment to be supplied with respect to normalized throttle angle and engine coolant temperature;
FIG. 4 is a logic flow block diagram of the operation of an engine control system in accordance with an embodiment of this invention; and
FIG. 5 is a logic flow block diagram of a portion of the logic flow block diagram of FIG. 4.
DETAILED DESCRIPTION OF THE INVENTION
In accordance with an embodiment of this invention, a speed throttle engine testing system 10 (FIG. 1) utilizes throttle angle as a load determination instead of, for example, measured mass air flow or calculated speed density. The throttle angle is a primary input to the control of spark timing, fuel injection and idle speed. Adaptive strategies are utilized to reduce the need for additional sensors. For example, an adaptive strategy can be based on feedback as a function of minimum throttle position.
Referring to FIG. 1, speed throttle engine testing system 10 includes an electronic engine control (EEC) module 11 coupled to an engine 12. EEC module 11 includes the following signal processing and storage: air charge calculation module 13, self test module 14, idle speed control (ISC) module 15, fuel calculation module 18 and spark advance calculation module 19.
Fuel calculation module 18 has an output applied to fuel injectors 20 which are coupled to engine 12. If desired, a heated exhaust gas oxygen sensor can be used to provide feedback correction of engine air/fuel ratio. Idle speed control (ISC) module 15 applies a signal to a bypass air solenoid 22 which in turn is coupled to a fuel charging assembly of engine 12. Spark advance calculation module 19 provides an output to a thick film ignition (TFI) module 23 which applies current to ignition coils 24 which in turn are coupled to spark plugs 25 of engine 12. A signal representing engine coolant temperature (ECT) is applied front: engine 12 to spark advance calculation module 19, fuel calculation module 18, and idle speed control module 15. A signal representing instantaneous throttle position (TP) is applied to air charge calculation module 13, fuel calculation module 18, and idle speed control module 15.
Referring to FIG. 2, the structure of electronic engine control module 11 is shown in block diagram. A custom central processing unit (CPU) 30 is coupled by two way communication to a custom electrically programmable read only memory (EPROM) 32. Custom CPU 30 is used to store the base spark table and the base fuel table information. CPU 30 receives signals from interface circuitry 33, and supplies signals to an idle speed control (ISC) bypass air circuit 34, injector drivers 35, and auxiliary drivers 36.
Drivers 36 have outputs to a fuel pump, a self test output and spark advance information. Interface circuitry 33 receives signals supplying information characterizing engine coolant temperature (ECT), throttle position (TP), self test input switch (STI), and crankshaft position. Since the engine management system in accordance with an embodiment of this invention uses throttle position for engine load indication, the accuracy of the throttle position sensor is relatively more important than the accuracy of the other sensors. Using adaptive correction, the lowest throttle position reading is assumed to be a closed throttle reading. This closed throttle position reading is used as a base for other throttle position readings indicating how much the throttle is open. Idle speed control bypass air circuit 34 provides a duty cycle output to the idle speed control bypass air solenoid. Injector drivers 35 have an output to fuel injectors.
Engine test system 10 uses three tables as indicated in FIGS. 3A, 3B and 3C. In FIG. 3A, an engine air charge table is a function of normalized throttle angle and engine speed. When a value for air charge is determined from the table of FIG. 3A, the air charge value is used as one axial input for the table in FIG. 3B. In FIG. 3B, the spark table is a function of engine speed on one axis and of engine air charge on the other axis. In FIG. 3C, a fuel adjustment table is a function of engine coolant temperature and normalized throttle angle.
Referring to FIG. 4, a block diagram illustrates the logic which occurs within (EEC) control module 11 which is coupled to engine 12 during engine testing. Interactive operation of an engine testing control system in accordance with an embodiment of this invention begins at block 41 with START. The logic sequence then goes to a block 42 where an engine warmup is determined by checking to see if the coolant temperature (ECT) is greater than a calibrated value (CV). Advantageously, the engine control strategy for idle speed is such as to run an engine at sufficiently high speeds to increase engine coolant temperature sufficiently fast for a relatively quick engine test. That is, the high speed idle engine operation is extended compared to normal operation of an engine installed in a car. If engine coolant temperature is below the calibrated value, logic flow proceeds to block 43 wherein there is provided an increase in engine speed for a predetermined time duration. If engine coolant temperature is greater than the calibrated value at block 42 or the timed duration of increased engine speed at block 43 has been complete, logic flow goes to a block 44 wherein engine self testing is initiated. The results of the self test are displayed at an output 45.
Referring to FIG. 5, a further breakdown of initiate self-test block 44 includes blocks 51 through 55, wherein various checks are performed and the results stored for output at block 45. Block 51 determines whether or not ECT is within a predetermined temperature range defined by magnitudes A and B. Block 52 determines whether or not ECT is above some predetermined temperature magnitude C. Block 53 determines whether or not throttle position is within a predetermined angular position range defined by angular positions D and E. Block 54 determines whether engine RPM is greater than predetermined magnitude F. Block 55 determines whether or not the duty cycle of the signal applied to the engine idle speed control valve is above a predetermined value G.
During operation of engine test system 10 the initial ECT sensor input determines the RPM at which to run the engine. Engine speed is controlled by the ISC valve. Self test block 44 makes determinations for: (a) ECT and TP outside the range of predetermined limits, (which may indicate either a fault in the engine electrical wiring harness or in the sensor itself); (b) ECT too low, (which may indicate that the sensor is faulty); (c) idle engine speed too low, (which may indicate that the ISC valve does not function or there is a fault in the engine wiring harness); (d) ISC duty cycle too low, (which may indicate that undesired air is being drawn in, e.g. a vacuum leak or a throttle plate that was not adjusted properly). Accordingly, engine testing system 10 allows the running of different types of engines with one single relatively low cost engine test system and verifies the integrity and functionality of the engine, engine wiring harness, ECT and TP sensors as well as idle speed control valve operation.
Various modifications and variations will no doubt occur to those skilled in the art to which this invention pertains. For example, the particular engine test module functional structure can be varied from that disclosed herein. These and all other variations which basically rely on the teachings through which this disclosure has advanced the art are properly considered within the scope of this invention. | An engine testing system tests an engine at the end of a production line by controlling the fuel charge and ignition spark timing of an operating engine as a function of engine speed and air charge. The test is accomplished without the need for mass air flow and manifold absolute pressure sensors. | 5 |
BACKGROUND OF THE INVENTION
This invention relates to a printer and, more particularly, to a sheet feeder which supplies/discharges sheets of paper to be printed.
In a sheet feeder of a printer, sheets to be printed are taken out of a hopper by a feed roller, transferred through a sheet guide to a platen, printed by a print head on the platen, and then discharged.
The printed sheets are inserted between a drive roller having a rubber surface and being fixed to a drive shaft and a driven roller having a rubber surface, and then the sheets are discharged as the rollers rotate.
However, there is a problem that the rubber rollers tend to deteriorate the printing quality, because the rubber material soaks non-dried ink immediately after the printing and the soaked ink is transferred to the sheet, thus incurring stains on the sheets.
In order to solve this problem, a sheet feeder having metal drive and driven rollers has been proposed.
Although these metal rollers are indeed hardly stained with ink, they involve new problems of slip of sheets and instable discharging operation.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide a sheet feeder which does not bring the ink stains.
It is another object of the invention to provide a sheet feeder which enables to feed sheets stably.
The foregoing objects are accomplished by providing a sheet feeder comprising a sheet supply section; a feed roller; a pair of a drive roller and a driven roller which seize the sheets therebetween, at least one of which contacts the printed face of the sheet being made of a material which is hard to be stained with ink when contacted to a printed sheet; a slip preventing means having a base means whose diameter is smaller than that of the drive roller and having a deformable means whose tip projects from the drive roller surface by a short length and bends in contact with the sheet in a small area when the sheet is located between the drive roller and the driven roller; and a sheet discharge section, whereby the deformable means transfers the sheet forcibly with equibrating the bend of the sheet.
The foregoing object is also accomplished in another embodiment by providing a rough faced roller which contacts a printed face of the sheets and has properties of being hard to be stained and of having a friction coefficient sufficient for transferring sheets without slipping.
BRIEF DESCRIPTION OF THE DRAWINGS
In the accompanying drawings:
FIG. 1 is a perspective view of a printer to which the invention is applicable;
FIG. 2 is a perspective view of the major part of a sheet feeder according to an embodiment of the invention;
FIG. 3 is a cross sectional view along the center line of FIG. 2;
FIG. 4 shows relations among a drive roller, a driven roller, and a secured bristle part during printing operation;
FIG. 5 shows relations among the drive roller, driven roller and the secured bristle part after discharging the sheet;
FIG. 6 is a perspective view of the major part of a sheet feeder according to another embodiment of the invention;
FIG. 7 is a cross sectional view of FIG. 6;
FIG. 8 shows a drive roller and a driven roller used in the sheet feeder according to an embodiment of the invention; and
FIG. 9 shows another embodiment of drive/driven rollers.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows an external view of a typical printer having a sheet feeder.
Referring to FIG. 1, a sheet feeder 102 is mounted on the printer body. In the sheet feeder, each of the sheets accumulated in a hopper 104 is drawn out by supply rollers (not shown) and sent to the printer. After printing, the printed sheet is discharged by discharging rollers 106 according to the invention and accumulated in the printed sheet stacker 108.
FIG. 2 shows the main part of the sheet feeder according to the invention and FIG. 3 shows a cross sectional view of the center part thereof.
Referring to the sheet feeder, the drive gear 7 engages with a platen gear 10 secured to a platen shaft 11 through idle gears 9 and 8. When the platen shaft 11 rotates, the drive gear 7 results in rotation, and a drive discharge roller 21 on the drive shaft 3, which is secured to the drive gear 7, rotates. In this embodiment, the number of the drive rollers 21 is four, and four driven discharge rollers 22 secured to a common driven shaft 4 contact the drive rollers 21, respectively. The driven roller 22 is made of rubber or material coated with rubber, and the driven shaft 4 is supported by bearings 6 free to rotate at both ends of the shaft 4. Bushes 5 for supporting the drive shaft are secured to a frame 14 and the driven gears 7, idle gears 8 and 9 are supported to the frame 14 in a manner of rotation free. Above the platen 12, a pair of sheet guides 13 and 14 which lead printed sheet to the entrance side of the drive roller 21, are provided.
The drive discharge roller 21 is made of metal with a smoothly finished surface. The metal roller, has an advantage of being hard to be stained with ink. But the friction coefficient is so small that the sheet will slip if the driven roller 22 is made to simply contact the drive roller 21. To solve this problem, the driven rollers 22 are forcibly synchronized with the drive rollers 21 by means of transmission gears 25 and 26 secured to the drive shaft 3 and driven shaft 4, respectively.
A roller 23 having a smaller diameter than the drive roller 21 is secured to the drive shaft 3 in the neibourhood of the drive roller 21. On the outer surface of the smaller roller 23, bristles 24 such as nylon bristles are set with the tips of bristles being projected from the outer diameter of the drive roller 21 by a short length f, as shown in FIG. 3.
FIGS. 4 and 5 show the shape and the function of the bristles 24 of the roller 23 according to an embodiment. In this embodiment, bundles of at least three bristles each of which has, for example a diameter of 0.1 mm, are planted on the outer cylindrical surface of the roller 23 linearly along the axis of the shaft, and at four portions at every 90° thereon.
When the sheet 20 to be discharged is supported between the drive roller 21 and the driven roller 22, as shown in FIG. 4, the bristles which are in contact with the sheet bend, and these bends of bristles are equilibrated with the bend of the sheet 20. When this equilibrium occurs, the tips of bristles bite the sheet 20. This brings a slipless transfer of the sheet 20 at the time of rotation of the drive shaft.
After discharging the sheet 20, the bent tips of the nylon bristles return to the former state, and as shown in FIG. 5, the tips of the bristles project out of the sheet 20.
The operation of the sheet feeder according to the invention will now be described hereinbelow.
The sheet 20 transferred by a pair of friction rollers 17 and 18 and wound around the platen 12, is subjected to impact by a print head 30 with an ink ribbon 19 between the print head 30 and the sheet 20.
The printed sheet 20 is guided by paper guides 13 and 14, and then discharged to A direction caught by the drive discharge roller 21 and the driven discharge roller 22 which rotates in contact with the drive roller 21. The drive roller 21 is driven by a platen gear 10 which rotates in (a) direction and which is secured to the platen shaft 11, and by idle gears 8 and 9 and a drive gear 7. During this discharging, the drive discharge roller with a smooth surface and the slip protecting means allows the sheet 20 to be discharged without ink stains and slips.
FIGS. 6 and 7 are a perspective view and a cross sectional view showing another embodiment of the invention, respectively. In FIGS. 6 and 7 different from FIGS. 2 and 3, a knurled metal drive roller 31 is used. The driven roller 32, small roller 33 and bristle section 34 correspond to the driven roller 22, small roller 23 and the bristle section 24, respectively and they have the same configurations and functions.
In this embodiment, the drive roller 31 is made of metal with knurling, so that the ink stain and slip of sheet are hardly generated.
In the above-mentioned embodiment, metal rollers are used as the drive roller. However, any material which is hard to be stained with ink, for example, synthetic resin such as polytetrafluoroethylene (Teflon), can be used.
Though the ink stain will be extremely decreased if the metal rollers are used, some staining is unavoidable in the long-term operation. In order to solve this problem, cleaning may be introduced by using a cleaning pad which is made of felt plate, etc.
Further, in the above-mentioned embodiments, a small roller having bristles is used. But any type of slip protecting means which enables sheets forcibly to be transferred in contact therewith in very small area, may be employed.
FIGS. 8 and 9 show cross-sectional views, along the plane perpendicular to the drive shaft, of other embodiments according to another aspect of the invention.
In FIG. 8, there are employed a cylindrical drive roller 41 and a cylindrical driven roller 42 which contact with each other in the outer surfaces, and both rollers rotate with their shafts which are in parallel. On the surface of the drive roller 41, there is formed a flame coated thin metal film 41a of 50 μm or less, preferably 35˜40 μm. Generally, a tungsten film is used but any metal film can be used if it is adapted for uniform coating and the flame coated film has a certain abrasion resistance.
Formation of the flame coated metal film is performed by utilizing a plasma coating of tungsten powder having an average grain size of not more than 50 μm, with rotation of the roller to obtain a uniform film thickness around the circumference.
According to the microscopic view of the flame coated surface, there are formed many fine projections. It is typical that the surface of the film has a roughness in which the average distance between adjacent tops is approximately 50 μm, because the surface of the roller can have proper friction against the sheet and have a property of being hard to be stained with ink when the printed sheet surface contacts.
In detail, there are observed micro-projections and depressions microscopically on the rough surface such as flame coated surface, so that the contact area between the sheet and the rough surface is very small and does not absorb ink, thus resulting in no transferring of ink and no deterioration of print quality. Besides, the friction coefficient of the surface is fairly large because of the above-mentioned micro-projections and depressions, and therefore reliable sheet discharge is possible without using the slip preventing means having bristles which may cause creases.
FIG. 9 also shows the combination of a drive roller 51 and a driven roller 52. In FIG. 9 different from FIG. 8, the surface of the drive roller 51 is knurled and the flame coated film 51a is formed thereupon. In this case, the combination of knurling and flame coating makes it possible to discharge sheets more smoothly.
The rough surface described above can be obtained by various methods other than flame coating. For example, sticking of small particles on a surface or roughing of the surface by shot blasting, may be employed.
The invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. The present embodiment is therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein. | A sheet feeder having a slip preventing mechanism having a deformable member whose tip projects from a drive discharge roller by a short length and bends in contact with a sheet to be discharged in a small area, when the sheet is located between the drive discharge roller and the driven discharge roller. The deformable member transfers the sheets forcibly with biting them. As one of the drive roller and the driven roller which contacts the printed face of the sheet is made of a material which is hard to be stained by ink when contacted to the printed sheet, neither stain nor slip incur. Alternatively, the surface of one of the discharge rollers may be made rough. | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] None
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH AND DEVELOPMENT
[0002] Not applicable
THE NAMES OF THE PARTIES TO A JOINT RESEARCH AGREEMENT
[0003] Not applicable
INCORPORATION-BY-REFERENCE OF MATERIAL SUBMITTED ON A COMPACT DISC
[0004] Not applicable
BACKGROUND OF THE INVENTION
Field of the Invention
[0005] The present invention relates generally to composite materials. More particularly, the present invention pertains to flexible ceramic fibers, and their use to form composite materials and methods of making the same. Even more specifically, the present invention relates to the fabrication of composite materials comprising flexible ceramics micro and nanofibers and polymers using electrospinning, forcespinning and blowspinning methods.
[0006] Description of the Related Art Including Information Disclosed Under 37 CFR 1.97 and 37 CFR 1.98
[0007] The following description of the art related to the present invention refers to a number of publications and references. Discussion of such publications herein is given to provide a more complete background of the principles related to the present invention and is not to be construed as an admission that such publications are necessarily prior art for patentability determination purposes.
[0008] Composites are materials that are made from two or more constituent materials with significantly different physical or chemical properties that, upon being combined, produce a resulting “composite” material with different characteristics than the constituent materials. The goal in making composites is usually to obtain a material with certain enhanced properties or characteristics when compared to the constituent materials.
[0009] The prior art reveals numerous examples of ceramic and polymer composite materials, including different combination rations of a ceramic and a polymer. Ceramic materials used in those composite examples include, but are not limited to: alumina, silica, zirconia, yttrium stabilized zirconia, Titania, and titanium carbide. Polymer materials used in those composite examples include, but are not limited to, polyvinyl alcohol, polymethyl methacrylate and polydimethylsiloxane.
[0010] The electrospinning process consists of driving a polymer solution jet through a high electric filed rendering a meso-scale fluid jet into nano-scale fibers. The electrospinning process as a method to manufacture “fine” fibers dates back to the early 1900s work of Morton (U.S. Pat. No. 705,691) and Cooley (U.S. Pat. No. 692,631). Morton's and Cooley's patents, as refined by Formhals (U.S. Pat. No. 2,158,416) in 1939, were marred by then current technology limitations. Consequently, the methods developed by Morton, Cooley and Fromhals did not teach a way to make nanofibers.
[0011] In 1995, Soshi and Reneker reintroduced the electrospinning process, as we know it today, by using then available scanning electron microscope (“SEM”) techniques thus resulting in the production of nanofibers. Further, Soshi and Reneker identified numerous applications for electrospun nanofibers in a myriad of fields like structures, textile, membrane and biomedical engineering. (See Sakar, et al., Materials Today, Vol. 13, No. 11, 2010).
[0012] Polymer micro and nanofibers fabricated with electrospinning were first reported decades ago. However, the first ceramic nanofibers produced from electrospinning were produced relatively recently in 2003. Nevertheless, those nanofibers were not flexible. Flexible ceramic materials comprising electrospun nanofibers have been previously reported even more recently, starting around 2006 (See U.S. Pat. Publication No. 2006/034948 to Reneker, et al).
[0013] More recently, a method to make nanofibers from a wide range of materials has been developed. That method is known as forcespinning. Forcespinning uses centrifugal force instead of electrostatic forces to spin into nanofibers solutions or solid materials (dissolved or melted). Forcespinning emerged as a faster and cheaper alternative to electrospinning. One can make ceramic nanofibers using forcespinning. Another method to fabricate micro and nanofibers of polymers and ceramics is blowspinning as disclosed and claimed in U.S. Pat. No. 8,641,960 to Medeiros. Blowspinning uses pressurized air to spin solutions into nanofibers. However, applicants could not find prior art examples of flexible ceramics being made using forcespinning or blowspinning.
[0014] Nonetheless, there are prior art examples of other small thickness flexible ceramics being made by using very thin depositions or growths of ceramic materials (See http://www.enrg-inc.com and http://www.camnano.com).
[0015] One of the main objectives of the invention embodied in the present application is to provide free standing, flexible and continuous ceramic films using either electrospinning, blowspinning or forcespinning. That material which is the subject of the present application will be referred to hereinafter as Flexiramics™. Specifically, electrospinning of ceramics normally yields rigid, non-woven mats of ceramic micro and nanofibers. Those mats are not continuous and flake shaped. In addition, a substrate that serves as mechanical support is needed. The present invention overcomes all of those shortcomings of the prior art.
SUMMARY OF THE INVENTION
[0016] Because of its physical and chemical properties, the free standing, flexible and continuous surface ceramic films, and the composites using the film of the invention embodied in the present application meet or exceed the requirements for many practical, industrial and commercial uses. For example, the material described and claimed herein can be used to: (1) replace the currently used flexible printed circuit boards substrates which are usually made using Polylmide (aka Kapton or PI) or PI with low ceramic fillers; and (2) replace some polymeric protective layers used for cable insulation (polyethylene with aluminum hydroxide filler).
[0017] Normally, Applicants work with 3% yttria-stabilized zirconia. However, Applicants have found that silica and Titania, thin layers of several metal oxides including, but not limited to alumina, zinc oxide, and perovskites can also become flexible.
[0018] The film composites of the present invention are bendable to a bending radius close to 0 as shown in FIG. 2 . Experimental data shows that the material of the present invention can undergo a fatigue test where it can be bent 45° and brought back to flat in a 3-point-bending test. Further, the material of the present invention can withstand over 2000 cycles of fatigue whereupon the material degrades but it does not break as illustrated by FIG. 1 .
DETAILED DESCRIPTION OF THE INVENTION
[0019] Objects, advantages and novel features, and further scope of applicability of the present invention will be set forth in part in the detailed description to follow, taken in conjunction with the accompanying drawings. The objects, advantages and novel features, and further scope of applicability of the present invention will become apparent to those skilled in the art upon examination of the following, or may be learned by practice of the invention. The objects and advantages of the invention may be realized and attained by means of the instrumentalities and combinations particularly pointed out in the appended claims.
[0020] A principal objective of the invention embodied in the present application is to make Flexiramics™ and to improve the mechanical strength (tensile) of the Flexiramics™ by using the method disclosed herein to make composite materials with several polymers. The polymers can be thermosets (a curing temperature is needed to create a full polymer cross-linking, typically between 20 and 300° C.) or thermoplastics (a melting temperature is needed to soften and make the polymer fluid, typically between 100 and 400° C.).
[0021] Specifically, Applicants have used polydimethylsiloxane (PDMS) as liquid polymer with Flexiramics™ to make composites. Applicants have prepared PDMS/Flexiramic™ composites, ranging from weight ratios of 0.1 to 99.9 of PDMS to Flexiramics™. Applicants achieved the very low ratios by using diluted PDMS precursor solutions. Dilution percentages typically ranged 70 and 90%. The preferred solvents used to dilute the PDMS precursors were toluene and hexane. The viscosity of the resulting diluted solution was typically between 80 to 200 Millipascal per Second (mPa·s).
[0022] Generally, to achieve that desired viscosity range, a pre-crosslinking at 60° C. was needed. Due to the low viscosity of the solution, the Flexiramic can be easily impregnated by applying the solution over the top of a sample extended on a flat and rigid surface. This can be achieved using a casting knife or a spray coating gun. Due to capillarity and gravity, the Flexiramic became completely impregnated with the solution.
[0023] Next, the polymer was thermally cured by placing the sample into an oven at temperatures between 60° C. and 90° C. The curing step can be achieved at temperatures as low as 20° C. with the only effect being longer curing times. The resulting maintained the desired fibrous structure due to the fact that Applicants applied the PDMS as a thin coating on every individual ceramic nanofiber. In the preferred embodiment of the invention, the coating was in the range of a few tenths to a few hundred nanometers.
[0024] Applicants achieved the desired high PDMS/Flexiramic ratios by embedding the Flexiramic in non-diluted PDMS precursor solutions. The non-diluted solutions' preferred viscosity range between 1500 and 15000 (mPa·s). Applicants then casted the non-diluted solutions on flat and rigid surfaces with preferred thickness between 0.1 to 5.0 millimeters (mm).
[0025] Next, the Flexiramic was deposited on top of the casted solution, thus allowing the solution to permeate through the entire sample via capillarity forces.
[0026] Next, the sample was thermally cured by placing the sample into an oven at temperatures between 60° C. and 90° C. The curing time was directly proportional to the thickness of the sample. For example, at 60° C., the curing time was one (1) hour.
[0027] The cured sample comprises a thick PDMS layer on one side (between 0.1 to 5.0 mm), and a thin PDMS layer of few micrometers on the other side, typically from 1 to 50 μm. On an alternative embodiment of the invention, Applicants prepared samples with thicker layers on both sides by casting an extra PDMS precursor layer on top of the thin PDMS layer. Applicants can easily control the thickness of that layer by modifying the viscosity of the PDMS precursor solution. In order to increase the viscosity of the PDMS, short thermal treatments at moderate temperature (between 30° C. to 60° C.) can be performed. Alternatively, Applicants can decrease the viscosity of the PDMS by mixing small amounts of toluene or hexane (1% to 100%) with the PDMS precursor solution.
[0028] In yet another alternative embodiment of the invention, polyethylene (PE) was used to prepare composite materials with the Flexiramic. In that embodiment, PE was melted at temperature above its melting point of 135° C. The melted PE was then applied on top of a Flexiramic applying sufficient pressure (typically between 1 to 10 kiloNewtons) for a complete embedding of the PE onto the Flexiramic. This was done using a hot-press melt equipment, which resulted in the application of sufficient pressure. The composite was then allowed to cool down to room temperature resulting different thickness ranging from 0.1 to 5.0 mm. The gradual calibration of the amount of PE results in being able to control the thickness of the layer. Therefore, a wide range of PE/Flexiramic ratios can be achieved.
[0029] Another embodiment of the invention comprises the use of polyurethane (PUR) for making composite materials. In that embodiment, the PUR precursor is melted under temperatures above 200° C. The melted PUR precursor is then applied on top of a Flexiramic using a pistol equipped with a slot die head. Next, the resulting PUR precursor/Flexiramic sample is thermally cured inside an oven at 100° C. The resulting composite embodiment has a thicknesses ranging typically from 0.1 to 5.0 mm.
[0030] Another embodiment of the invention can be achieved by double side coating after the curing of the first layer. The thickness of the layers can be controlled by adjusting the opening of the slot die, and by manipulating the viscosity of the molten PE by increasing or decreasing the temperature used to melt the polymer. Those controlling steps result in a broad range of PE/Flexiramic ratios that can be predictably modified depending on the application.
[0031] Another embodiment of the invention can be obtained by using Polyimide (PI) as the polymeric material for the fabrication of composite materials with the Flexiramic. In order obtain that embodiment of the invention, Applicants dissolved poly(amic acid) in N-Methyl-2-pyrrolidone (NMP) resulting in the precursor solution with typical viscosities of 1000 to 10000 mPa·s. In order to obtain alternative embodiments of the precursor solution, Applicants used solvents like NMP and γ-butyrolactone. The solution was then casted on a flat and solid surface and the Flexiramic was deposited on top, thus allowing the solution to penetrate through the entire sample via capillarity forces. Next, the sample was dried at 80° C. typically for 1 h and then was thermally dried by applying heat up to 300° C. using a hot plate or a furnace, typically for 30 minutes. Upon allowing the sample to cool down, it presents polyimide films on both sides of the Flexiramic, typically ranging from 1 to 100 μm. That thickness can be modified by casting thinner or thicker poly(amic acid) films.
[0032] The method of the present invention can be executed using a pistol with a slot die head, as well as other techniques like the doctor blade or the casting knife. The resulting samples were dense but the fibrous structure of the Flexiramic can be maintained by diluting the poly(amic acid) with higher amounts of solvents in order to decrease the viscosity down to a range of e.g. 50 to 300 mPa·s. Then, nanofibers could be individually coated with thin polyimide coatings as described above for the PDMS.
[0033] These composite materials can also be prepared with different polymers like polypropylene (PP), polyether ether ketone (PEEK), Polyethylenimine (PEI), cyanate esters, epoxy resins, polyesters, vinyl esters, urea-formaldehyde, allylics, polyphthalamide (PPA), polyphenylene sulfide (PPS) and polytetrafluoroethylene (PTFE). The techniques applied would be the same than before, namely, spray coating, pistol with slot head die, doctor blade, casting knife and hot press melt.
[0034] This composite materials retain their flexibility and can be bended to very low bending radius without breaking or being damaged, even when the polymeric content does not even exceed 5%. Additionally, these composites present a great enhancement of the thermic properties as compared with the polymers themselves. For example, the composite made with PDMS catches fire two times slower than freestanding PDMS foil (of the same thickness) when exposed to a methane flame. The composite made with PE can even retard the flame at least twice and up to one order of magnitude more than free standing PE of the same thickness (see video). Furthermore, when the composite material is burning, there is no dripping of any part, preventing the fire to spread. Instead, a protective crust is formed. Another example to illustrate the excellent thermic properties of the composite material prepared with polyimide is that the sample can resist temperatures as high as 500° C. without losing flexibility and flatness when the ceramic content is 25%. Instead, a freestanding polyimide film of the same thickness, starts wrinkling at temperatures around 300° C. or higher because the glass transition of the polyimide is surpassed.
[0035] In general, Flexiramics can be used to create bendable composites with higher thermal endurance and better flame retardancy. The weight ratio of ceramic/polymer can range from very low, being a dense polymer film with very low content of ceramic fibers, to very high, being a porous films (non woven) with the ceramic fibers individually coated with polymer.
[0036] The Flexiramic-based composite material of the present invention is flexible in a macroscopic scale (as a mat) and at a single fiber scale. The mechanical properties of the material of the present invention can be attributed to several factors:
The elongated shape comprising a fiber diameter that ranged between 20-10000 nm thus allowing bendability; The fiber lengths are measurable up to 4 cm, however, they are pressumed to be longer; Small crystal sizes ranging from 1 to 100 nm with smaller grains allowing increased ductility; Fiber smoothness ranging between 0.05 and 5 nm Root Mean Square Roughness (Rq); and The fibers are not physically attached to each other in the non woven mat form of the material of the present invention which allows the fibers to freely move and have a more bendable material at a macroscopic scale.
[0042] The composite materials of the present invention comprising non-woven ceramic micro and nanofibers (Flexiramics) and polyimide present optimal thermal stability. At temperature as high as 400-500° C., the composite does not wrinkle nor loses flexibility and therefore, increases the temperature threshold at which it can be used. Additionally, the material is light and has a low density (10-40 g/m 2 ).
[0043] The composite materials of the present invention comprising Flexiramic and polyethylene present optimal fire retarding properties. Applicants have found that it takes at least twice as long for that material to start catching when compared with materials of the prior art being used for similar purposes. Additionally, once the material of the present invention starts combusting, no parts drip and the fire can be contained because a crust of the calcined material is formed and held onto the fibers. That crust also prevents the flame from propagating through the material.
DESCRIPTION OF THE PREFERRED EMBODIMENT OF THE INVENTION
[0044] The preferred embodiment of the present invention is prepared by the method comprising the following steps:
[0045] 1. Preparation of a precursor solution, the precursor solution comprising the metallic ions or inorganic polymer (sol) that will form the final metal oxide (ceramic), as well as polymer to increase the viscosity.
a. Sol-gel can be used as precursor but it is not necessary as dissolved salts provide the required viscocity. b. Bigger fiber diameters can be achieved by increasing the polymer content and/or precursor content. This must be tuned to achieved the desired fiber diameters. c. The material's viscocity must be kept between 0.01 and 1000 Pascal-second (Pa·s) at a shear rate of 0.1 s −1 in order to spin usable fibers. d. The solid content (polymer plus precursor) must be above 15% by weight in order to obtain the required deposition. f. The utilized solvents must be carefully chosen in order to provide an evaporation rate that is high enough. This can be done, but is not limited to, by mixing water with alcohols as it increases the evaporation rate.
[0051] 2. Spinning the precursor solution by using forcespinning or electrospinning.
a. The spinning parameters have little or no effect on the flexibility of the resulting polymeric fiber. b. Instead, the spinning parameters are tunable so that the spinning step can result in a continuous film or polymeric fiber. This must be adapted to each different solution.
[0054] 3. Annealing the fibers obtained from the spinning process which are not ceramic after the spinning. Instead, the spun fibers are polymeric fibers comprising ionic metal or inorganic polymer.
a. Annealing the fibers until all the organic content is burned out and the metal ions oxidize to form a ceramic. b. A typical thermal profile is generated as shown in FIG. 3 which displays parameters of the annealing process comprising heating/cooling rate, annealing temperature and dwell time. It must be noted that the profile is essential to be tuned to obtain the desired cristallinity presented above. c. The parameters of the annealing process being distinct as to each material composition. For example, heating/cooling rates as low as 0.5° C./min and as high as a thermal shock (from room temperature to the annealing temperature). d. The annealing temperature having to be above the crystallization point thus allowing the formation of ceramic material. e. The dwell time ranging from 0 to 5 hours.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0060] The accompanying drawings, which are incorporated into and form a part of the specification, illustrate an embodiment of the present invention and, together with the description, serve to explain the principles of the invention. The drawings are only for the purpose of illustrating a preferred embodiment of the invention and are not to be construed as limiting the invention. The scope of the invention can only be limited by specific limitations contained in the appended claims.
[0061] Simple sketches that allow one not necessarily familiar with the technical area to which this application pertains to gain a visual understanding of the invention.
[0062] FIG. 1 : A photographic depiction of Flexiramic embedded in polyimide having a thick layer on one side (top) and a thin layer on the other side (bottom).
[0063] FIG. 2 : A graphic showing the Flexiramics 3 point bending fatigue test measured in force versus time.
[0064] FIG. 3 A typlical thermal profile which displays parameters of the annealing process comprising heating/cooling rate, annealing temperature and dwell time.
[0065] FIG. 4 : A graphical depiction illustrating the dependency of the crystal size of YSZ nanofibers on the annealing step. The annealing vary from convection oven to microwave (MW). The heating and cooling rate range from 1° C./min to thermal shock (RTA).
[0066] FIG. 5 : A microscope picture of the formed flexible YSZ non woven fiber mat.
[0067] FIG. 6 : Photographic depictions of the resulting flexible ceramic YSZ material (Flexiramics™) clerly showing the material's bendability and its pure ceramic nature by being not flammable.
[0068] FIG. 7 : A graphical depiction illustrating the dependence of the roughness of YSZ nanofibers on the annealing step. The annealing vary from convection oven to microwave (MW). The heating and cooling rate range from 1 C/min to thermal shock (RTA).
[0069] FIG. 8 : A viscosity profile measurements of different spinable solutions. | The present application discloses and claims a method to make a flexible ceramic fibers (Flexiramics™) and polymer composites. The resulting composite has an improved mechanical strength (tensile) when compared with the Flexiramics™ alone. Several different polymers can be used, both thermosets and thermoplastics. Flexiramics™ has unique physical characteristics and the composite materials can be used for numerous industrial and laboratory applications. | 1 |
BACKGROUND OF THE INVENTION
The present invention is directed to a multiple needle sewing machine or an embroidering machine, and more specifically to the needle selection means associated with the multiple needles.
In a conventional multiple needle sewing machine such as that disclosed in U.S. Pat. No. 4,474,124, granted to Masayuki Yamazawa on Oct. 2, 1984, a lever device may be located at any one of a plurality of positions corresponding to that of a specific needle bar in order to act as the needle bar changing means. However, the transfer of the lever from one position to another is a relatively cumbersome operation and can not satisfy the requirement for a quick needle bar changing operation.
SUMMARY OF THE INVENTION
The present invention provides a new and improved multiple needle sewing machine which is relatively quick and easy to operate without the aformentioned drawbacks. The needle bar changing operation is performed by a single quick action.
The present invention is directed to a new and improved multiple needle sewing machine having an overhanging arm, a first shaft rotatably mounted in said arm, a first lever fixedly connected at one end portion thereof to one end portion of said first shaft, spring means for rotating said first shaft and the other end portion of said lever in an upward direction, first and second needle bars each having thereon a middle notch and an upper notch adjacent the upper end thereof, first solenoid means operatively connected to said first lever, an adjusting member connected to the other end portion of said first lever and having an upper portion and a lower portion, said lower portion of said adjusting member being disposed in engagement with said upper notch of said first lever bar at a height above the upper dead point thereof, said upper portion of said adjusting member being urged in the downward direction for aligning an upper end portion of said needle bar with that of said second needle bar upon downward movement of said first lever upon energization of said first solenoid means, a sliding member moveable in the vertical direction by a crank means and engaged in said middle notch of said second needle bar, a common block member in which said first and second needle bars are moveably mounted in the vertical direction, said block member being moveable across the feeding line of the workpiece to be sewn, while said upper portion of said first needle bar is in alignment with that of said second needle bar, a second shaft fixedly connected at one end portion to said block member and moveable with said block members so as to disengage said sliding member from said middle notch of said second needle bar, engage said sliding member with said middle notch of said first needle bar, disengage said lower portion of said adjusting member from said upper notch of said first needle bar and engage said lower portion of said adjusting member with said upper notch of said second needle bar, a third shaft rotatably mounted in said arm, a second lever fixedly connected at a base portion thereof to one end portion of said third shaft, said second lever being connected at a distal end portion thereof to the other end portion of said second shaft, second solenoid means operatively connected to said second lever, said second solenoid means being energized at a predetermined time t 1 after the energization of said first solenoid means and being deenergized after a predetermined time t 2 subsequent to the deenergization of said first solenoid means, said predetermined time t 1 being sufficient to allow alignment of said upper end portion of said first needle bar with the upper end portion of said second needle bar, said predetermined time t 2 being sufficient to allow movement of said block member and said needle bar upwardly above the upper dead point simultaneously with the upward rotation of said adjusting member, said first lever and first shaft, a first locking member having a cavity therein and being fixedly mounted on the other end portion of said first shaft, a second locking member having a first projection fitted in said cavity of said first locking member and a second projection fixedly mounted on the other end portion of said third shaft, said locking member being swung upon rotation of said third shaft while said block member is being moved and said first locking member is being separated from said second locking member as a consequence of downward rotation of said first shaft, said second projection of said second locking member being brought into engagement with said cavity of said first locking member as a consequence of upward movement of said first shaft after deenergization of said first solenoid means and completion of the swinging movement of said second locking member due to energization of said second solenoid means, and a control circuit for controlling said first solenoid means and said second solenoid means.
The foregoing and other objects, features, and advantages of the invention will be apparent from the following more particular description of a preferred embodiment of the invention as illustrated in the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front view of the needle bar changing mechanism for a multiple needle sewing machine.
FIG. 2 is a left side view of FIG. 1.
FIG. 3 is a view of the locking mechanism for preventing an unexpected needle bar changing operation.
FIG. 4 is a plan view of the rear portion of the arm of a multiple needle sewing machine.
FIG. 5 is an exploded view of a needle bar and associated mechanisms.
FIG. 6 is a plan view illustrating the relationship between the needle bars and an adjusting member.
FIG. 7 is a timing chart showing the relationship of the components in a needle bar changing operation.
FIG. 8 is a schematic diagram of a circuit for controlling the needle bar changing operation.
DETAILED DESCRIPTION OF THE INVENTION
The multiple needle sewing machine 10 according to the present invention includes an overhanging arm 11. A first shaft 12 is rotatably mounted on the rear portion of the arm 11. One end portion 12a of the first shaft 12 is located in the arm 11 and is connected to one end portion 13a of a first lever 13 by any suitable means. Thus, the other end portion 13b of the first lever 13 is swingable about the axis of the first shaft 12 upon rotation thereof. A torsion spring 14 is provided about the first shaft 12 with one end portion thereof connected to a collar 15 fixedly mounted on the first shaft 12 by means of a bolt 16. The other end portion of the spring 14 is disposed in engagement with an adjacent surface of the arm 11. The force of the spring 14 acts upon the first shaft 12 so that the first lever 13 is rotated upwardly in a counterclockwise direction, as viewed in FIG. 2.
A first locking member 17 is fixedly mounted on the other end portion of the shaft 12 and terminates in an axially extending portion 17a having a cavity 17b therein. The axially extending portion 17a of the first locking member 17 is disposed in opposing relation to a second locking member 18 having a first projection 18a and a second projection 18b. Due to the rotation of the first shaft under the influence of the spring 14, the axially extending portion 17a of the first locking member 17 is brought into engagement with the second locking member 18 with the projection 18a disposed in the cavity 17b. Thus, excessive rotation of the first shaft 12 is prevented.
The other end portion 13b of the first lever 13 is provided with a bent portion disposed parallel to the first shaft 12 and an adjusting member 19 is fixedly mounted thereon. The adjusting member 19 is provided with an upper portion 19a, a side portion 19b adapted to be secured to the end portion 13b of the first lever 13, and a lower portion 19c having a semi-circular cutout 19d. An abutting member 20 is secured to the lower surface of the upper portion 19a, and is provided with a semi-circular cross section.
A first needle bar 21 and a second needle bar 22 are arranged for vertical reciprocating movement in a common block member 23. The first needle bar 21 is formed at the upper end thereof with an upper notch 21a and a middle notch 21b is located adjacent the middle portion of the needle bar. Similarly, the second needle bar 22 is also provided with an upper notch 22a and a middle notch 22b. As shown in FIGS. 1 and 2, the upper notch 21a of the first needle bar 21 is disposed in engagement with the lower portion 19c of the adjusting member 19 at a position above the upper dead center point of the first needle bar 21 and the middle notch 22b of the second needle bar 22 is disposed in engagement with a projection 24a on the vertically reciprocable memeber 24 which is moveable along a guide member 25. The slide member 24 is operatively connected to a crank mechanism 26 driven by the main shaft 27. Thus, the sliding member 24 is reciprocated in the vertical direction together with the second needle bar 22 during the operation of the sewing machine.
A bracket 28 is secured to the arm 11 by means of bolts 29, and a first solenoid 30 is supported on a horizontal portion 28a of the bracket 28 by means of a nut 31. A plunger 30a of the first solenoid 30 is pivotally connected to the first lever 13 by means of a pin 32. The first solenoid 30 is electrically connected in the control circuit 50 of FIG. 8, which includes a first selecting switch 53. Upon closure of the switch 53, the solenoid 30 will be energized to move the plunger 30a in the downward direction to cause the lever 30 to move in the clockwise direction, as viewed in FIG. 2. The downward movement of the end portion 13b of the lever 13 causes the first needle bar 21 to move in the downward direction to bring the upper end portion 21c of the first needle bar 21 into alignment with the upper end portion 22c of the second needle bar 22.
A second shaft 33 is moveably supported on a boss 34 integrally formed within the arm 11. One end portion 33a of the second shaft is coupled to a boss portion 23a on the block member 23, which is moveable across the feeding line of the work to be sewn between a pair of horizontally spaced stops 35 and 35'. The other end portion 33b of the second shaft 33 is provided with an annular groove 36 between a pair of axially spaced rings or washers 37 and 37'. Collars 38 and 38' are fixedly secured to the second shaft 33 by means of bolts 39 and 39' and cushion rings 40 and 40' are disposed between the respective collars and rings.
A second lever 40 is provided with a spherical end portion 40b which is disposed in the groove 36. The base end portion 40a of the lever 40 is clamped on one end portion 41a of a third shaft 41 by means of a bolt 42. A rod 43 is secured to the middle portion of the second lever 40 by means of a bolt 44, and the opposite end 43b of the rod 43 is pivotally connected to the plunger 45a of a second solenoid 45. The solenoid 45 is supported on a bracket 46 secured to the inside of the arm 11 by means of bolts 47. The plunger 45a of the second solenoid 45 is moveable between a fully extended and a fully retracted position. transfer of the plunger 45a from the fully extended position to the fully retracted position, or vice versa, begins simultaneously with the energization of the second solenoid 45, a predetermined time t 1 subsequent to the energization of the first solenoid 30.
Upon swinging movement of the second lever 40 due to the operation of the solenoid 45, the second shaft 33 and the block member 23 are moved as a single unit in the horizontal direction.
The second locking member 18 is fixedly mounted on the opposite end portion of the third shaft 41, and is swingable upon rotation of the third shaft 41 simultaneously with the swinging movement of the second lever 40 as long as the first locking member 17 is out of engagement with the second locking member 18.
The circuit 50 includes CPU, a first switch 51, and a first power supply 52, all of which are connected in series. The CPU is also electrically connected to the first selecting switch 53, and a second selecting switch 54. The first selecting switch 53 may not be brought into the ON condition while the second selecting switch 54 is in the ON condition or the first needle bar 21 is in operative connection with the sliding member 24. The second selecting switch 54 may not be brought into the ON condition while the first selecting switch 53 is in the ON condition or the second needle bar 22 is in operative connection with the sliding member 24. The CPU is connected to the base of a first switching transistor 55. The emitter of the transistor 55, a second power supply 56, a second switch 57, the first solenoid means 30, and the collector of the transistor 55 are connected in series. Similarly, the emitter of a second switching transmitter 58, a third power supply 59, a third switch 60, the second solenoid means 45, and the collector of the transistor 58 are connected in series, and the base of the transistor 58 is connected to the CPU.
The first switch 52, the second switch 57, and the third switch 60 may be closed/opened simultaneously, and the needle bar changing operation is initiated after closure of these three switches. Upon closure of the first selecting switch 53, a signal is supplied to base of the first switching transisitor 55 thereby energizing the first solenoid means 30. After a predetermined time t 1 subsequent to the energization of the first solenoid 30, the second solenoid means 45 is energized. The second solenoid means is deenergized after a predetermined time t 2 subsequent to the deenergization of the first solenoid means 30.
In operation, upon the closure of the second selecting switch 54, the first solenoid means 30 is energized so that the plunger 30a, thereof, is moved downwardly to rotate the first lever 13 and the first shaft 12 in the clockwise direction, as viewed in FIG. 1. Therefore, the upper end portion 21c of the first needle bar is brought into correspondence with the upper portion of the second needle bar 22. The rotation of the shaft 12 will cause a first locking member 17 to be moved away from the second locking member 18 so that the first projection 18a will be disengaged from the cavity 17b of the first locking member 17. After completion of the downward movement of the first needle bar 21 and separation of the first locking member 17 from the second locking member 18, the second solenoid means 45 is energized to rotate the second lever 40 together with the third shaft 41 in the counterclockwise direction, as viewed in FIG. 1. Thus, the second shaft 33 will be moved to the right as viewed in FIG. 1, and the block member 23 will be moved in the same direction. As soon as the block member 23 is brought into engagement with the stopper 35', the first solenoid means 30 is deenergized and the first lever 13 and the adjusting member 19 are lifted or moved back to the original positions due to the spring biased movement of the first shaft 12.
Since the projection 24a of the sliding member 24 is brought into engagement with the middle notch 21b of the first needle bar 21 instead of the middle notch of the second needle bar 22, and the lower portion 19c of the adjusting member 19 is brought into engagement with the upper notch 22a of the second needle bar 22 instead of the upper notch of the first needle bar 21 during rightward movement of the block member 23, the second needle bar 22 will be moved upwardly to a position above the upper dead center point thereof due to the rotation of the first shaft 12.
The counter-clockwise rotation of the third shaft 41, as viewed in FIG. 1, will cause the second locking member 18 to also move in the counter-clockwise direction so that the second projection 18b of the second locking member 18 is brought into opposing relation to the cavity 17b before the deenergization of the first solenoid means 30. Upon deenergization of the first solenoid means 30, the cavity 17b of the first locking member 17 is brought into engagement with the second projection 18b of the second locking member 18 due to the rotation of the first shaft 12. Thus, the second needle bar 22 will be at rest and the first needle bar 21 will be ready for operation.
While the invention has been particularly shown and described with reference to a preferred embodiment thereof, it will be understood by those in the art that various changes in form and details may be made therein without departing from the spirit and scope of the invention. | A multiple needle sewing machine is provided with two needles which are mounted for vertical reciprocating movement in a block which may be laterally shifted between a first position and an second position wherein the first and second needles will be selectively engaged with a vertically reciprocating drive member. A first solenoid is energized to lower a needle bar holding member which is engaged with the inoperative needle to lower the inoperative needle to a position corresponding to the operative needle prior to the lateral shifting of the needles by means of a second solenoid. Subsequent to the lateral shifting of the needle bars to engage the vertical reciprocating member with the previously inoperative needle bar, the previously operative bar will be raised upwardly by the needle bar holding device upon deenergization of the solenoid by a suitable spring. | 3 |
BACKDROUND OF THE INVENTION
The present invention relates to a system for guiding optical elements, as defined in the preamble of claim 1 .
Such systems are used, for example, in zoom systems, in which optical assemblies such as lenses or lens groups are moved relative to one another. For example, in a zoom system, the individual zoom-system components made up of individual lenses or lens groups are moved relative to one another along the optical axis of the zoom system.
Patent Publication WO 96/34306 describes a play-free lens guide system in which lens slides are held by magnets to two guide rods and are movable therealong without play. In that system, one or more lenses are mounted in lens slides. The lens slide is moved along one of the guide rods by rotation of a drum cam which is engaged by a cam follower disposed on one side of the lens slide. The term “lens slide” as used in that patent and herein is understood to refer to mechanical components adapted to receive lenses or mounted lens groups. These lenses or lens groups may also be axially or laterally adjustable. The lenses or lens groups are guided by the lens slide along their optical axis as the lens slide itself is moved along an axis parallel to the optical axis. Thus, lens slides constitute a special type of carrier for optical elements.
Since such lens slides are acted upon only at one (first) guide rod, they tend to become rotated or tilted out of alignment. Rotation about the one (first) guide rod is prevented by engagement on the second guide rod.
Overall, large magnetic forces are required here to secure the lens slides on the guide rods in a substantially tilt-free manner. However, these large magnetic forces result in high friction and stiffness of adjustability, for example, of a zoom adjustment.
BRIEF SUMMARY OF THE INVENTION
It is, therefore, an object of the present invention to provide a play-free guide system for optical elements, in particular for lenses of a zoom system, which moves more easily or smoothly during adjustment than those known in the prior art.
It is a feature of the guide system of the present invention that in order to provide magnetic attraction between the carrier for an optical element, particularly a lens slide (see definition above) for at least one lens, and at least one guide rod at least partially made of magnetic or magnetizable material, the carrier is provided with a magnetic or magnetizable wheel adapted to roll along the at least one magnetizable guide rod as the carrier is displaced therealong. The term “wheel” as used herein is understood to refer in particular to a component that is rotatable about an axis. Moreover, the term “wheel” used herein is not meant to impose any limitation on the axial dimension, i.e., the width, of the peripheral rolling surface, so that thin or disk-like bodies, as well as wide, i.e., roller- or cylinder-like bodies, are also encompassed by this term. It should be noted that according to the present invention the magnetizable or magnetic wheel rolls in the direction parallel to the longitudinal axis of the guide rod. Hereby, the contact area between (cylindrical) rod and wheel is minimized.
The term “axis” as used herein may include both the (mathematical) axis of rotation, and a (physical) axis or axle about which the wheel rotates. Depending on the context, it is also possible that only one of these two meanings applies.
The term “magnetizable” as used herein is understood to mean “made partially or entirely of a magnetizable material”. The term “magnetizable”, which is used herein in particular for the guide rod and the wheel, is intended to include in particular permanent magnetic materials (also referred to as “hard magnetic” or magnetically hard materials) and soft magnetic (magnetically soft) materials.
According to the terminology commonly used in the art, permanent magnetic materials are understood to be materials which are composed of a magnetizable material, for example, a ferromagnetic material such as iron, cobalt, nickel or ferrite, and which produce a permanent static magnetic field without relying on an external magnetic field or a flow of electric current.
Similarly, in accordance with conventional terminology, soft magnetic materials are understood to be, for example, ferromagnetic materials which can easily be magnetized in a magnetic field caused, for example, by the presence of a permanent magnet. Examples of soft magnetic materials include metals and metal alloys based on the ferromagnetic metals iron, cobalt and nickel. Ceramic materials, such as metal oxide based ferrites, may also be mentioned merely by way of example.
Thus, in accordance with the terminology used, the present invention especially comprises guide rods having soft magnetic properties in combination with wheels having permanent magnetic properties and being adapted to roll thereon and, conversely, guide rods having permanent magnetic properties and wheels having soft magnetic properties and being adapted to roll thereon. Also included is a combination of guide rods having permanent magnetic properties and wheels which also have permanent magnetic properties to roll thereon.
Thus, magnetic attraction forces of similar magnitude may be provided between the carriers and guide rods, in particular to prevent tilting, while at the same significantly reducing the occurring frictional forces and effects. This significantly increases the ease of movement of the guide system during adjustment. The magnetizable wheels according to the present invention are both easy to mount and capable of providing a constant force.
Advantageous embodiments of the system or device according to the present invention are the subject matter of the dependent claims.
In accordance with a preferred embodiment, the magnetizable wheel comprises a ring-shaped permanent magnet adapted to roll along the guide rod. Such a permanent magnet (ring magnet) has a ring-shaped south pole in a first plane and a corresponding, ring-shaped north pole in a second plane (located thereabove). The ring-shaped permanent magnet is adapted to roll along the guide rod. It is a feature of this embodiment that the number of parts required is very small.
In accordance with another preferred embodiment, the magnetizable wheel comprises a soft magnetic (magnetically soft) wheel adapted to roll along the guide rod, at least one permanent magnet being provided on at least one (axial) side of the soft magnetic wheel. Overall, therefore, a magnetizable wheel is provided which, according to the terminology used herein, has permanent magnetic properties. This embodiment comprises both the provision of a suitable number of small permanent magnets arranged around a side or side face of the wheel, and the provision of a ring-shaped magnet on the soft magnetic wheel. Providing a number of (smaller) permanent magnets turns out to be less expensive than using a ring-shaped magnet.
Advantageously, permanent magnets are provided on both sides of the soft magnetic wheel.
In both embodiments, it is advantageous to distribute a number of magnets uniformly around the circumference of the wheel (either on one or both sides).
The poles of the at least one permanent magnet are preferably axially aligned with each other with respect to the axis of the soft magnetic wheel. This means, for example, that the north poles of all permanent magnets are directly adjacent or in direct contact with the wheel, while the south poles, which are adjacent to the north poles, have a greater (axial) distance from the wheel. Of course, an arrangement in reverse order is also possible (with the south poles directly on the wheel).
Care must be taken to ensure that all magnets on one side of the wheel have the same axial orientation.
In the case that permanent magnets are provided on both sides of the wheel, it is advantageous to ensure that the poles of the permanent magnets on different sides of the wheel are oriented in opposite directions with respect to each other. That means, for example, that on both sides, all north poles are farther away from the respective side faces of the wheel than the south poles, or vice versa.
Advantageously, the physical axis (axle) about which the magnetizable wheel rotates as it rolls along the guide rod is made from a non-magnetizable or non-magnetic material. This makes it possible to prevent magnetic flux from passing through the axis (axle), which would reduce the magnetic forces acting between the carrier and the guide rod. However, the axis (axle) may also be made of a magnetizable material. In this case, it is advantageous to ensure that sufficient clearance is provided between the axis (axle) or axis of rotation and the at least one permanent magnet formed on the wheel.
It is also preferred that the magnetizable wheel be mounted rotatably about a (physical) axis (axle), either with or without using a ball bearing for supporting the wheel. The use of a ball bearing allows particularly easy movement during adjustment. On the other hand, in comparison with the prior art, the frictional forces caused by the magnetic attraction are reduced to such an extent that the wheel may also be rotatably supported directly; i.e., without using a ball bearing.
Moreover, it is preferred that the peripheral rolling surface (contact surface) of the magnetizable wheel have a profiled shape. By adapting such a profile to match the shape of a guide rod, it is advantageously possible to further stabilize the rolling motion of the wheel along the guide rod.
It is preferred to provide two guide rods, along each of which rolls at least one magnetizable wheel. In this embodiment, tilting and rotation out of alignment is prevented in a particularly effective manner.
In a further preferred embodiment, one guide rod is engageable by at least one pair of magnetizable wheels arranged in a V-shape with respect to one another. With this feature, the special advantages offered by a V-shaped groove in terms of resistance to tilting and rotation may also be used in the present invention.
The system according to the present invention is particularly suitable for use in microscopes, in particular stereomicroscopes, or in macroscopes, where accurate positioning of lenses is of essential importance, and where any tilting and/or rotation of the lenses with respect to their optical axis reduces the image quality.
BREIF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
The present invention will now be described in more detail with reference to the attached drawings, in which:
FIG. 1 is a cross-sectional view showing a prior art lens guide system from below;
FIG. 2 is a side view of the system of FIG. 1 ;
FIG. 3 is a bottom view corresponding to that of FIG. 1 , showing a first preferred embodiment of the system according to the present invention;
FIG. 4 is a side view (corresponding to that of FIG. 2 ) of the embodiment of FIG. 3 ;
FIG. 5 is a detailed cross-sectional bottom view of a portion of another preferred embodiment of the present invention;
FIG. 6 is a bottom view corresponding to that of FIG. 5 , showing a further preferred embodiment of the present invention;
FIG. 7 is a bottom view corresponding to that of FIG. 5 , showing another preferred embodiment of the present invention;
FIG. 8 is a bottom view corresponding to that of FIG. 5 , showing a further preferred embodiment of the present invention; and
FIG. 9 is a bottom view corresponding to that of FIG. 5 , showing yet another preferred embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The prior art guide system or device for a stereomicroscope illustrated in FIGS. 1 and 2 is denoted as a whole by reference numeral 100 . The device shown includes two guide rods 112 , 114 , guide rod 112 being designed as the main guide rod, and guide rod 114 being designed as an anti-rotation means. A lens slide 120 is movable along guide rods 112 , 114 ; i.e., in the directions of double-headed arrow 101 shown in FIG. 2 . This movement corresponds to a movement along (i.e., parallel to) the optical axes of lenses 109 mounted in lens slide 120 . The illustrated arrangement of two lenses disposed at the same height corresponds to the configuration of a stereomicroscope in which two parallel observation beam paths are provided. Typically, a zoom system has two or more such lens slides which are arranged one above the other and displaceable on guide rods 112 , 114 .
Lens slide 120 has a V-shaped groove 134 by which it is guided along guide rod 112 .
Reference numeral 110 denotes a drum cam which is engaged by a cam follower 111 of lens slide 120 . When drum cam 110 is rotated about its longitudinal axis 110 a manually or by motor means, a force F is exerted on lens slide 120 . A first component of this force acts in the direction of guide rod 114 ; i.e., in the direction of double-headed arrow 101 , and a second force component acts tangentially to drum cam 110 ; i.e., perpendicularly into or out of the plane of the paper of FIG. 2 .
The aforementioned first force component in the direction of double-headed arrow 101 must overcome a holding force and the resulting friction of lens slide 120 on guide rods 112 , 114 .
Because of the distance of cam follower 111 from guide rod 112 , there is a tendency of lens slide 120 to tilt out of a plane perpendicular to guide rod 112 . In the event of such tilting, the centers of lenses 109 migrate out of their proper positions as a result of the aforementioned V-shaped configuration of guide groove 134 . Such tilting turns out to be very disadvantageous, especially in stereomicroscopes.
Furthermore, the aforementioned second force component (tangential to drum cam 110 ) creates a tendency for lens slide 120 to rotate about the longitudinal axis of guide rod 112 . This rotation also causes the centers of lenses 109 to migrate out of their proper positions.
In order to counteract these tilting and rotational movements, permanent magnets are formed on lens slide 120 which interact with guide rods 112 , 114 made of magnetizable (e.g., soft magnetic) material, producing magnetic attraction. A permanent magnet, denoted as 142 , which interacts with guide rod 114 is shown particularly well in FIG. 1 . Two magnets interacting with guide rod 112 are denoted as 144 . The holding force mentioned above is generated or substantially affected by these magnets. During rotation of the drum cam, the lens slide slides along the guide rods, held thereto by the magnetic force. Here, the permanent magnet is supported in a pocket 142 a . Such a pocket makes it possible to provide a defined distance between the permanent magnet and the guide rod. The pocket may be manufactured, for example, from a magnetizable (soft magnetic) material, such as metal.
Permanent magnets 144 interacting with guide rods 112 serve to hold lens slide 120 to guide rod 112 and to prevent the aforementioned tilting movements.
Magnet 142 , which interacts with guide rod 114 , also serves to prevent rotation of lens slide 120 about guide rod 112 . It does so by attracting lens slide 120 onto guide rod 114 . To this end, the lens slide (shell 142 a in the variant shown) has a flat surface 115 extending parallel to the aforementioned V-shaped groove 134 , which is disposed on the other side of lens slide 120 for engagement with further guide rod 112 .
Magnet 142 , which is disposed behind this surface 115 ; i.e., behind shell 142 a , at a distance from rod 114 , presses this surface against rod 114 . If surface 115 and V-groove 134 are not exactly parallel, then there will be a conflict; i.e., the lens slide will rotate out of position. In this case, typically, not the entire surface 115 is in contact with rod 114 , but only an edge thereof, which also causes abrasion. This requirement of parallelism of the surfaces is eliminated in accordance with the present invention by using a wheel and by a point contact thereby produced, as will be discussed in greater detail below.
Overall, very large magnetic forces are required to hold lens slide 120 to the guide rods 112 and 114 against the action of the aforementioned force F and the force of gravity, and possibly against acceleration forces, which may occur, for example, in response to an impact. In this connection, the force of gravity to be compensated is dependent on the (variable) spatial orientation of the stereomicroscope. In the extreme case, the force of gravity acts in the same direction as one of the aforementioned components of force F. In this case, too, the magnetic force produced must be sufficient to compensate for the total arising force.
Canting of V-shaped groove 134 with respect to the plane 116 passing through the central axes of guide rods 112 , 114 also results in increased abrasion.
However, the high magnetic forces that are required to avoid these disadvantages and which are provided by the interaction of magnets 142 , 144 with the guide rods cause high friction and increased resistance to movement of lens slide 120 during adjustment.
Overall, the prior art requires a lens slide that has very small tolerances, because the holding force of the magnets used is highly dependent on their distance from the respective guide rods. In order to keep the occurring magnetic forces within tight tolerance limits, it is therefore necessary to provide for very accurate mounting of the magnets and/or adjustment of the distances between the magnets and the guide rods.
A first preferred embodiment of the present invention will now be described with reference to FIGS. 3 and 4 . Similarly to the prior art described above, the guide system of the present invention (denoted as a whole by reference numeral 300 ) includes two guide rods 312 , 314 having soft magnetic properties and a lens slide 320 displaceable on said guide rods parallel to an optical axis 400 . Lens slide 320 has cam follower 311 , which engages a drum cam 310 . When drum cam 310 is rotated, a force F is exerted on lens slide 320 , moving lens slide 320 along guide rods 312 , 314 . The force components acting as mentioned in the description of the prior art must be compensated here as well.
In this embodiment, lens slide 320 is formed with a magnetizable wheel 370 having permanent magnetic properties, said wheel being mounted on lens slide 320 such that it is rotatable about an axis of rotation 370 a . Magnetic interaction between this wheel 370 and soft magnetic guide rod 314 produces magnetic attraction between wheel 370 and guide rod 314 . During displacement of lens slide 320 , wheel 370 rolls along guide rod 314 while maintaining the force of magnetic attraction.
The magnetic properties of wheel 370 are selected or dimensioned so as to provide the required holding force at guide rod 314 . Since wheel 370 is able to roll along guide rod 314 as lens slide 320 is displaced, the frictional forces occurring in the process can be minimized, as compared to the prior art. Therefore, if desired, the holding force can be selected to be of a higher magnitude than is possible in the prior art. There is no need for fine adjustment of the distance between the wheel and the guide rod because the wheel rolls on the guide rod.
The guidance of lens slide 320 on further guide rod 312 can also be accomplished using such magnetizable or permanent magnetic wheels. In the representation of FIG. 3 , a pair of such wheels 380 , 382 are provided, which are mounted on lens slide 320 such that they are rotatable about respective axes of rotation 380 a and 382 a , and are adapted to roll along guide rod 312 as the lens slide is displaced. Wheels 380 , 382 are arranged at an angle with respect to each other, so that the guidance of lens slide 320 along guide rod 312 is similar to that provided by the V-shaped groove in accordance with the prior art. In this embodiment, one such pair of wheels is provided, as is shown schematically in FIG. 4 . Thus, FIGS. 3 and 4 show an embodiment having a pair of wheels provided at rod 312 , the magnets 344 provided further above being configured in accordance with the prior art. It should be noted that these magnets could also be configured as a pair of wheels. Such an embodiment would then include a total of two pairs of wheels.
As an alternative to the angled or V-shaped arrangement of wheels 380 , 382 , as shown in FIGS. 3 and 4 , it is also conceivable to provide only one wheel, and to configure said wheel to have a, for example, V-shaped peripheral surface on which it rolls along guide rod 312 . Examples of this will be given below.
Preferred embodiments of the wheels used in accordance with the present invention will now be described with reference to FIGS. 5 through 9 , which each show guide rod 314 and the adjacent portion of lens slide 320 . The wheels shown each have side faces 370 ′ and a peripheral rolling surface 370 ″. Similar designs may also be provided to engage guide rod 312 . In this case, and in the embodiments described hereinbelow, the wheels may be arranged, in particular, in the shape of a V with respect to each other. In all embodiments described hereinafter, the wheel has permanent magnetic properties. It is noted once again that it is also within the scope of the present invention that the guide rod may be permanently magnetic, and that in this case, a wheel interacting therewith may be soft magnetic, for example.
In the embodiment shown in FIG. 5 , wheel 370 includes a wheel 372 which is ferromagnetic or made from soft magnetic material and which is mounted by a ball bearing 374 so that it is rotatable about the (mathematical) axis of rotation 370 a.
Permanent magnets 378 are mounted on a side face 370 ′, i.e., on one side, of soft magnetic wheel 370 . It is possible, for example, to provide a number of permanent magnets 378 arranged laterally around the circumference of wheel 372 . In such a configuration, the individual permanent magnets 378 must be oriented such that identical poles (represented by the north pole in FIG. 5 ) are in contact with side face 370 ′ of wheel 372 , so that the magnetic flux passing through the north pole, wheel 372 , guide rod 314 and the south pole altogether produces magnetic attraction between wheel 370 and guide rod 314 . The corresponding magnetic field lines are shown schematically in FIG. 5 . In such a configuration, the magnetic flux (circuit) is closed in the outer or edge region of wheel 372 .
Of course, it is equally possible to attach the respective south poles of magnets 378 to side face 370 ′ of wheel 372 so as to achieve a corresponding magnetic flux.
Instead of using individual magnets 378 , it is also possible to provide a ring magnet having a corresponding polarity.
As for the design of wheel 370 , it is advantageous if the (non-rotating) axis axle 390 ; i.e., the immediate vicinity of the axis of rotation 370 a , is made from non-magnetizable, for example, non-ferromagnetic, material so as to prevent magnetic flux from passing through the axis (axle), which would reduce the magnetic attraction between the wheel and the guide rod. However, it should be noted that axis (axle) 390 may also be made of magnetizable material. In this case, it is advantageous to ensure that the permanent magnets have a sufficient distance from axis (axle) 390 and axis of rotation 370 a.
Advantageously, axis (axle) 390 has a first end 390 a which is inserted or pressed into the ball bearing, a central portion 390 b configured as an axial stop, and a second end 390 c inserted in a mount 320 a of lens slide 320 . Of course, axis (axle) 390 shown here serves merely as an example. Other suitable shapes are also possible.
As can be seen in FIG. 5 , soft magnetic wheel 372 rolls along guide rod 314 as lens slide 320 is displaced, the spacing between magnets 378 and guide rod 314 remaining constant in the process. This is useful in order to be able to adjust the magnetic force to a desired magnitude and to further reduce frictional forces. However, it is also possible to allow contact between magnets 378 and guide rod 314 as wheel 370 rolls therealong.
Another variant of a wheel according to the present invention is shown in FIG. 6 . This variant differs from that shown in FIG. 5 mainly in that magnets 378 are provided on both sides of wheel 372 . This embodiment allows a relatively large magnetic force to be provided within a very small space. The magnetic flux produced is illustrated schematically by the field lines.
In this embodiment, too, soft magnetic wheel 372 is rotatably mounted in a ball bearing 374 , shown schematically here. Here, too, the axis (axle) (not shown in greater detail here) is made from non-magnetizable material.
FIG. 7 shows another preferred embodiment of a wheel 370 that can be used in accordance with the present invention. First of all, it can be seen that, unlike the embodiments shown in FIGS. 5 and 6 , the respective south poles of individual magnets 378 (or, when a ring-shaped magnet is used, the south pole of this magnet) are in contact with the surface of soft magnetic wheel 372 .
It is a feature of this embodiment that the bearing arrangement for the wheel is simplified as compared to the embodiments of FIGS. 5 and 6 . Specifically, no ball bearing is provided here. Rather, wheel 372 is rotatably mounted, directly on axis (axle) 390 .
Finally, FIGS. 8 and 9 show further preferred embodiments of the magnetizable wheels according to the present invention. It is a feature of the embodiments of FIGS. 8 and 9 that the peripheral rolling surfaces 370 ″ of wheels 370 have a profiled shape, the respective profiles being complementary to the particular guide rod 314 on which the wheels are adapted to roll.
In the embodiment of FIG. 8 , peripheral surface 370 ″ of the magnetizable, in particular permanent magnetic wheel 370 is circular arc-shaped and, therefore, conforms to the circular cross section of guide rod 314 with any desired accuracy.
In this connection, it is also conceivable for the guide rod and/or the peripheral surface of the wheel to have other curvatures, such as elliptical curvatures.
In the embodiment of FIG. 9 , peripheral wheel surface 370 ″ has a V-shaped profile. This profile, too, improves the guidance of the wheel on the guide rod.
In the embodiments of FIGS. 8 and 9 , the bearing means for supporting wheels 370 on axis (axle) 390 correspond to those of FIG. 7 and, therefore, will not be described again in detail here. A bearing arrangement using one or more ball bearings would also be conceivable.
The guide system of the present invention is suitable for use in Greenough-type stereomicroscopes, in stereomicroscopes having parallel zoom telescopes, and also in single-channel zoom macroscopes.
The magnetizable wheels are supported with as little play as possible. For this purpose, it is possible to use, for example, commercially available precision components and/or precision ball bearings.
In addition to the aforementioned advantageous effects in terms of the reduction of friction, magnetizable wheels 370 that are used in accordance with the present invention are characterized by less abrasion compared to the sliding components used in the prior art.
Moreover, wheels provide a point contact which offers greater resistance to tilting than the area contact according to the prior art. Without the use of wheels which roll along guide rods, it is impossible to achieve a point contact. This advantage has been discussed earlier herein in connection with V-shaped grooves such as are known in the prior art, and also in connection with a V-shaped arrangement of two wheels.
The guide system of the present invention is particularly suitable for use in stereomicroscopes, where it is crucial that, during adjustment of the zoom system, the positionable lens elements of the observation channels do not become offset or tilted relative to the optical axis of the zoom system. | A system for guiding optical elements, in particular lenses, along an optical axis of a microscope, in particular a stereomicroscope, or of a macroscope, guide system including at least one guide rod which extends parallel to the optical axis and is at least partially made from a magnetizable material, and further including a carrier for the optical elements, the carrier being displaceable along the at least one guide rod and providing magnetic attraction between itself and at least one guide rod; for providing magnetic attraction, including at least one magnetizable wheel adapted to roll along the at least one guide rod while rotating about an axis as the carrier is displaced; the at least one guide rod (312, 314) being made of magnetizable material and/or the magnetizable wheel being at least in part permanently magnetic. | 6 |
This is a continuation of application Ser. No. 791,865, filed Nov. 13, 1991: which is a continuation of application Ser. No. 590,204, filed Sep. 28, 1990, now abandoned; which is a continuation of application Ser. No. 213,387 filed Jan. 10, 1988, now U.S. Pat. No. 4,967,799; which is a division of application Ser. No. 941,494, filed Dec. 15, 1986, now U.S. Pat. No. 4,766,662; which is a division of application Ser. No. 641,081, filed Aug. 15, 1984, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a plastic abrasion-resistant sleeve for protecting hose and a method for protecting hose.
2. Prior Art Statement
Because of fluctuations in the supply of energy, automobiles have been made increasingly more compact. Due to the downsizing of engine compartments, many underhood components are located in close proximity to the radiator hose. To prevent wear on such radiator hose due to contact with underhood components, an integral abrasion-resistant EPDM (ethylene-propylene-diene-monomer) rubber oversleeve has been used in some prior applications to protect the radiator hose. In such prior applications, the protective rubber oversleeve is disposed around the radiator hose during construction of such hose. However, the disposal of such rubber oversleeve is labor intensive and increases the chance that the hose will be scrapped since gases are sometimes trapped between the hose and the oversleeve. Trapped gases expand during vulcanization and sometimes cause delamination of the hose.
Also, since the water carried by the radiator hose, under running conditions, becomes very hot, and rubber loses abrasion resistant properties when subjected to heat over a period of time, the abrasion resistance of the EPDM abrasion resistant sleeve diminishes with age.
It is known in the art to provide a helical rubber protector for a hose as is illustrated by Patterson in U.S. Pat. No. 1,977,775.
It is known in the art to provide a protective cover for an insulated pipe bend comprising a corrugated band material, which is formed on the pipe bend and which is cut lengthwise into two or more parts as illustrated by Aleniusson in U.S. Pat. No. 4,054,985.
It is known in the art to provide an abrasion resistant flexible hose which employs a number of rubber bumpers distributed on the hose, as illustrated by Brunelle et al in U.K. Patent 1,327,659.
It is known in the art to provide a plastic conduit having a slit therein for protecting electrical wires in an automobile.
It is also known in the art to provide a plastic protective sleeve, having a slit, over hose carrying ambient temperature fluid on an automobile engine.
Langner, in U.S. Pat. No. 4,261,671 illustrates a corrugated pipe having an internal liner which is used for deep water applications.
Corrugated pipe used for other applications are also illustrated by Stearns, U.S. Pat. No. 3,490,496 and Jousson, U.S. Pat. No. 4,160,466.
SUMMARY OF THE INVENTION
In accordance with the present invention there is provided an abrasion-resistant protective sleeve for covering a radiator hose. The sleeve of the invention has an annularly corrugated external surface comprising a plurality of projections integrally formed in said sleeve. The projections of the sleeve are substantially evenly distributed, are substantially the same size, are substantially stationary relative to one another, yet provide flexibility in the sleeve. The corrugated sleeve is slit along its longitudinal axis to provide easy application to and removal from the hose. In its preferred embodiment, the corrugated sleeve is made of a plastic that is substantially unaffected by high temperatures.
Further, in accordance with the present invention, an improved method of protecting a hose from abrasion is provided in which an abrasion resistant protective sleeve is applied to a hose. The improvement in the method comprises the steps of providing a corrugated plastic sleeve having a slit along its longitudinal axis, making said plastic sleeve using a plastic that is substantially unaffected by high temperatures, bending the plastic sleeve to the shape of the hose, spreading the plastic sleeve at the slit along its longitudinal axis, and slipping the protective sleeve over the hose by moving the hose through said slit.
It is an object of the present invention to provide an improved method of protecting rubber hose subject to high temperatures against abrasion.
It is another object of the present invention to provide an improved protective sleeve for protecting rubber hose.
Other aspects, embodiments, objects, and advantages of this invention will become apparent from the following specification, claims and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings show present preferred embodiments of this invention, in which:
FIG. 1 illustrates a section of an abrasion-resistant protective sleeve;
FIG. 2 illustrates a close up view of a portion of the protective sleeve illustrating some dimensions of the preferred embodiments;
FIG. 3 illustrates a protective sleeve which has been bent to the shape of a hose, and spread to a position where it can be slipped over a hose; and
FIG. 4 illustrates a hose having a protective sleeve thereover.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Reference is now made to FIG. 1 of the drawings which illustrates a protective sleeve of the present invention which is designated generally by the reference numeral 10. The projections 12 and troughs 14 define the annularly corrugated structure of the protective sleeve. The slit 16 traverses the length of the protective sleeve and is aligned with the longitudinal axis of the sleeve. The inside diameter 18 may be varied depending on the size of the hose that is to be protected.
Referring now to FIG. 2, in the preferred embodiment, the height of the projections, defined as the distance between projection 12 and trough 14, as represented by arrow 15, will generally be about 0.2 inch. The distance between projections 12 is represented by arrow 17, and generally will be about 0.35 inch.
The corrugations of protective sleeve 10 provide flexibility which makes it possible to bend sleeve 10 to nearly any desired shape. Because sleeve 10 is flexible, and because of the presence of slit 16 in sleeve 10, it is possible to install the protective sleeve 10 on a hose just prior to packaging. (See FIG. 4). Also, the protective sleeve 10 can be removed or repositioned if necessary. Thus, since the protective sleeve of the present invention is adapted to be placed on a curved hose after the hose has been completely constructed, the problem encountered by the EPDM rubber oversleeve used previously to protect radiator hoses, namely the trapping of gases between the rubber oversleeves and the hose prior to vulcanization, is avoided.
It has been found that plastic compounds have abrasion properties superior to EPDM rubber. Also, plastic is much lighter than EPDM rubber. For example, a typical EPDM rubber sleeve was found to have a weight of 0.21256 lb. A plastic sleeve of the same size was found to have a weight of 0.04295 lb. Thus, a plastic sleeve of the present invention has about 1/5 the weight of EPDM rubber oversleeves used previously. Any plastic that is substantially unaffected by high temperatures and is suitable for forming a plastic hose may be used in the invention. In its preferred embodiment, the plastic materials used for making the protective sleeve will be selected from polypropylene and polyester and copolymers thereof.
The body of the sleeve of the invention can be made by conventional means known in the art of making plastic hose.
Although it will be apparent to those skilled in the art that the protective sleeve can be made in any desired dimension, in its preferred embodiment for the protection of radiator hose, the corrugations will have a depth of about 2/3 the pitch of said corrugations and about 1/10 the outside diameter of said sleeve. The inside diameter (I.D.) of the sleeve will be about 1.6 inches and the outside diameter (O.D.) will be about 2 inches.
Referring now to FIGS. 3 and 4, which illustrate the method of the present invention, in which hose 22 is protected from abrasion when a protective sleeve 10, made as described above, is placed over a completed hose prior to packaging. Because of the flexibility provided by the corrugations, protective sleeve 10 may be bent to the shape of the hose which is to be protected. The slit 16 defines edges 20 which may be spread apart to permit the sleeve to fit over hose 22. Although natural resiliency to a large extent causes the edges 20 of the plastic sleeve 10 to close after sleeve 10 has been applied, after sleeve 10 has been positioned as desired on hose 22, pressure may be applied to sleeve 10 in order to close the gap further between edges 20 such that sleeve 10 fits snugly on hose 22. Because of the flexibility and resiliency of the plastic materials used to make sleeve 10, if at a later time it is desired to reposition sleeve 10 on hose 22, the same procedure can be used. Also, in the event that sleeve 10 needs to be replaced, the above described procedure can be used to remove an old sleeve 10 and replace it with a new sleeve 10 without removing hose 22 from its position in the apparatus. Thus, sleeve 10 can be positioned as needed on a hose without disassembling the apparatus in which the hose is used.
The following example illustrates the superior properties of plastic that is substantially unaffected by high temperatures for its use in protecting rubber products against abrasion.
EXAMPLE
Additional advantages of the plastic protective sleeve of the present invention over the prior art EPDM protective sleeve are illustrated by the following data comparing the abrasion resistance of EPDM rubber and polypropylene.
______________________________________ (Polyproylpene) (EPDM) * *______________________________________Tensile strength (psi) 2324 2448 1246 1452Elongation (%) 217 193 425 300Tear Die C (#/in) 891 867 174 187Abrasion (mg loss) 109 118 324 1566Tabor #18 wheel1000 gms/1000 cyclesDurometer (Shore A) 95 95 67 78Wt. Loss -- 0.2% -- 5.15%______________________________________ *Denotes the properties of the material after being held at a temperature of 260° F. for 7 days. (aging test)
The tensile strength, elongation, tear resistance and abrasion resistance are indicative of the expected wear properties of the protective sleeve. The data of this example illustrates that the tensile strength, tear resistance and abrasion resistance of polypropylene is much greater than the corresponding properties in EPDM rubber. Thus, the wear resistance of polypropylene as compared to EPDM rubber, particularly as measured by the abrasion loss, would be expected to be correspondingly greater.
The Durometer measurement measures the hardness of the two materials. The Durometer reading illustrates that polypropylene is harder than EPDM rubber.
More importantly, as shown by the results of the aging test (exposure to heat and air), the properties of polypropylene are less subject to change with time. Thus, where EPDM rubber is subject to a considerable change in abrasion resistance with age, (1566 mg loss as compared to 324 mg loss), the abrasion resistance of polypropylene is relatively constant (118 mg loss as compared to 109 mg loss).
While present exemplary embodiments of this invention, and methods of practicing the same have been illustrated and described, it will be recognized that this invention may be otherwise variously embodied and practiced within the scope of the following claims. | The present invention relates to a plastic abrasion resistant protective sleeve for covering a radiator hose. The sleeve of the invention has an annularly corrugated external surface comprising a plurality of projections and troughs formed in said sleeve. The projections are substantially evenly distributed and have a substantially uniform size. The sleeve has a slit along its longitudinal axis which provides for easy application to or removal from the hose, and is made of plastic that is substantially unaffected by high temperatures. A method of using said protective sleeve for protecting a radiator hose from abrasion also is provided. | 5 |
[0001] This application incorporates by reference of Taiwan application Serial No. 90213251, filed Aug. 3, 2001.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention relates in general to an apparatus for supporting a monitor, and more particularly to an apparatus for supporting a liquid crystal display (LCD) and rotating the LCD with respect to the base.
[0004] 2. Description of the Related Art
[0005] In order for a monitor, such as a liquid crystal display (LCD), to be rotated forward and backward, the supporting apparatus of the monitor or the LCD need an angle adjustment design. Generally, the apparatus for supporting the LCD comprises a supporting arm for leading the rotation of LCD, wherein the supporting arm is fastened to the lower side of LCD.
[0006] [0006]FIG. 1A is a side view of a conventional apparatus for supporting the LCD. The conventional apparatus for supporting the LCD comprises a shaft 102 , the angle control elements 104 a and 104 b , and the clasps 106 a and 106 b mounted on the shaft 102 . Additionally, a pedestal 108 is provided for the apparatus for supporting the LCD. During assembly, the assembled shaft 102 is inserted through the holes of the pedestal 108 and the supporting frame 110 , and then secured by the screw caps 112 a and 112 b . The frictional torques on the two ends of the shaft 102 are produced, due to the rotation of apparatus, and the magnitudes thereof are different. For example, one end of shaft 102 (close to the screw cap 112 a ) produces 45 kg/m of frictional torque, and the other end (close to the screw cap 112 b ) produces 25 kg/m of frictional torque. Also, the shaft 102 is a combination of sectional cores; for example, two cores are respectively situated in the right and left sides of the angle control element 104 a . The supporting frame 110 embedded in a supporting arm can be rotated in a small angle range by gently applying an external force; meanwhile, the whole shaft 102 is rotated with respect to the supporting frame 110 . If greater external force is applied to the supporting frame 110 , the supporting frame 110 can be rotated to a larger angle; meanwhile, only one core is rotated with respect to the supporting frame 110 and the other core is sustained in the stationary state.
[0007] [0007]FIG. 1B and FIG. 1 are side views of the angle control elements in FIG. 1A. It is assumed that the LCD can be rotated in the range of 2 degrees forward and 60 degrees backward. There is a cut on the upper edge of the angle control element 104 a , as shown in FIG. 1B. The cut, divided by the central line (dash line), is split into a 2-degree angle and a 20-degree angle. There is a cut on the lower edge of the angle control element 104 b , as shown in FIG. 1C. The cut, divided by the central line (dash line), is split into two 60-degree angles. When the supporting frame 110 of the LCD is vertical to the base, the central lines of the angle control elements 104 a and 104 b are parallel to the clasps 106 a and 106 b , respectively. When the LCD is rotated, the shaft 102 is rotated with respect to the supporting frame 210 , and the clasps 106 a and 106 b respectively slide along the cuts of the angle control elements 104 a and 104 b . When the clasps 106 a and 106 b hit the risen edges of the angle control elements 104 a and 104 b , rotation of the supporting frame 110 stopped. If the supporting frame is rotated in the range of 2 degrees forward to 20 degrees backward, the whole shaft 102 is driven. If it is desired to rotate the supporting frame 110 to 60 degrees backward, then a larger force is needed for driving the shaft core at the left side of the angle control element 104 a ; meanwhile, the shaft core at the right side of the angle control element 104 b is sustained, and the clasp 106 keeps sliding along the edge of the cut of the angle control element 104 b until hitting the risen edge thereof.
[0008] According to the description above, the conventional apparatus for supporting the LCD has a drawback of highly cost due to the combination of the two sectional cores. In addition, magnitude of the frictional torques on the two ends of the shaft 102 are different, the end of the shaft 102 producing less frictional torque being weaker than the other end and easier to be damaged. Also, manual adjustment for adjusting the produced torques is required during assembly. It is time-consuming and labor-intensive. If the diameter of the core is increased for bearing the larger external force, the size of the apparatus for supporting the LCD also increases. Additionally, a pedestal is required on which the apparatus for supporting the LCD is mounted, thereby restricting the potential for developing a lighter and smaller base of the monitor.
SUMMARY OF THE INVENTION
[0009] It is therefore an object of the invention to provide an apparatus for supporting a monitor, in which the mechanical apparatus to rotate the monitor with respect to the base has great position effect, and the durability of the components of the apparatus is improved because the components are not easy to be aged.
[0010] According to the objective of the invention, an apparatus for supporting a monitor is provided, wherein the monitor connected to the base is rotatable. The apparatus comprises a supporting frame, a latching assembly, and a shaft assembly, wherein the latching assembly and the shaft assembly are mounted on the supporting frame. The supporting frame has a first sidewall and a second sidewall. The latching assembly comprises a tenon, wherein two ends of the tenon are a protrusive portion and a conjunctive portion. Between the protrusive portion and the conjunctive portion is the main body of the tenon. The protrusive portion projects through the second tenon hole of the second sidewall. Also, a control bar connected to the tenon is used for driving the tenon. The shaft assembly comprises a rotation control unit, a shaft base, and a plurality of washers. There are a first U-shaped cut and a second U-shaped cut in the edge of the rotation control unit. When the supporting frame is rotated, the protrusive portion slides along the edge of the first U-shaped cut and the hook slides along the edge of the second U-shaped cut, so that the monitor can be rotated in a first angle range. By moving the control bar, the protrusive portion will not couple to the first U-shaped cut and move toward the interior of the supporting frame, so that the monitor can be rotated in a second angle range.
[0011] According to the objective of the invention, another apparatus for supporting a monitor is provided, comprising a supporting frame, a lock assembly, and a shaft assembly. The supporting frame has a first sidewall and a second sidewall. The lock assembly comprises a lock pin and a spring. The ends of the lock pin are a protrusive portion and a conjunctive portion for receiving the spring. The spring is used for providing elastic recover force acting on the protrusive portion, so as to project the protrusive portion behind the second sidewall. There are a first U-shaped cut and a second U-shaped cut in the edge of the rotation control unit. The protrusive portion is coupled to the surface of the rotation control unit. The hook couples to the second U-shaped cut. When the supporting frame is rotated, the protrusive portion slides along a surface of the rotation control unit and the hook slides along the edge of the second U-shaped cut, so that the monitor can be rotated in a first angle range. When the supporting frame is rotated to a predetermined angle, the lock pin is pushed by the elastic recover force of the spring, so as to project the protrusive portion behind the second sidewall. If the supporting frame is further rotated, the protrusive portion is consequently uncoupled from the first cut, so that the monitor can be rotated in a second angle range.
[0012] Other objects, features, and advantages of the invention will become apparent from the following detailed description of the preferred but non-limiting embodiments. The following description is made with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] [0013]FIG. 1A (prior art) is a side view of a conventional apparatus for supporting the LCD;
[0014] [0014]FIG. 1B and FIG. 1C (prior art) are side views of the angle control elements in FIG. 1A;
[0015] [0015]FIG. 2A is a perspective view of the LCD assembled with the apparatus for supporting the monitor according to the first embodiment of the invention;
[0016] [0016]FIG. 2B is a side view of the LCD assembled with the apparatus for supporting the monitor according to the first embodiment of the invention;
[0017] [0017]FIG. 3A is a disassembled view of the apparatus for supporting the monitor according to the first embodiment of the invention;
[0018] [0018]FIG. 3B is a perspective view of the tenon of FIG. 3A;
[0019] [0019]FIG. 3C is a front view of the rotation control unit of FIG. 3A;
[0020] [0020]FIG. 3D shows the ranges of the angles of the rotation control unit of FIG. 3A;
[0021] [0021]FIG. 3E is a perspective view of the shaft base of FIG. 3A;
[0022] [0022]FIG. 3F is a perspective view of the washers of FIG. 3A;
[0023] [0023]FIG. 4A is a perspective view of the assembled apparatus for supporting the monitor according to the first embodiment of the invention, while the LCD is vertical to the base;
[0024] [0024]FIG. 4B is a side view of the apparatus of FIG. 4A;
[0025] [0025]FIG. 5A is a perspective view of the assembled apparatus for supporting the monitor of the invention, while the LCD with the retracted is protrusive portion of the tenon is tilted backward at 25 degrees;
[0026] [0026]FIG. 5B is a side view of the apparatus of FIG. 5A;
[0027] [0027]FIG. 6A is an enlarged perspective view of the apparatus for supporting the monitor according to the second embodiment of the invention;
[0028] [0028]FIG. 6B is a perspective view of the lock pin of FIG. 6A;
[0029] [0029]FIG. 6C is a front view of the rotation control unit of FIG. 6A;
[0030] [0030]FIG. 6D shows the angles of the rotation control unit of FIG. 6A;
[0031] [0031]FIG. 7A is a perspective view of the assembled apparatus for supporting the monitor according to the second embodiment of the invention, while the LCD is vertical to the base;
[0032] [0032]FIG. 7B is a side view of the apparatus of FIG. 7A;
[0033] [0033]FIG. 8A is a perspective view of the assembled apparatus for supporting the monitor according to the second embodiment of the invention, while the LCD is tilted backward to 25 degrees; and
[0034] [0034]FIG. 8B is a side view of the apparatus of FIG. 8A.
DETAILED DESCRIPTION OF THE INVENTION
[0035] The apparatus for supporting a monitor of the invention, particularly for connecting the liquid crystal display (LCD) and the base, allows the mechanical pivoting of the LCD on the base within a certain range. Also, the invention is further designed so that the LCD equipped with the apparatus can be folded to 90 degrees, for increased portability. In the preferred embodiments, the LCD rotating in the range of 2 degrees forward to 25 degrees backward and further folding to 90 degrees is taken for illustration. In the first embodiment (example 1), the purpose of positioning the LCD is achieved by cooperation of a rotation control unit and a tenon. In the second embodiment (example 2), the purpose of positioning the LCD is achieved by cooperation of a rotation control unit and a lock pin.
[0036] In the following description, the preferred examples are taken for illustrating the invention, but the invention is not limited hereto. Also, to avoid obscuring the invention, well-known elements not directly relevant to the invention are not shown nor described. Accordingly, the specification and the drawing are to be regarded in an illustrative sense rather than a restrictive sense.
EXAMPLE 1
[0037] [0037]FIG. 2A is a perspective view of an LCD assembled with the apparatus for supporting the monitor according to the first embodiment of the invention. In FIG. 2A, the LCD 202 is connected to the base 204 by two supporting arms 206 a and 206 b . FIG. 2B is a side view of the LCD assembled with the apparatus for supporting the monitor according to the first embodiment of the invention. In FIG. 2B, the LCD is tilted forward, away from the vertical central line 212 , and positioned in the first angle 214 (set up as 2 degrees herein). The LCD is tilted backward away from the vertical central line 212 and positioned in the second angle 216 (set up as 25 degrees herein). Also, the LCD can be folded backward to 90 degrees, which is in parallel with the base 204 . A belt-shaped portion is further created in the base 204 , so that the user can easily carry the LCD by holding the belt-shaped portion. The apparatus for supporting a monitor is equipped inside the supporting arm 206 a or 206 b . The supporting arm 206 a (or 206 b ) is assembled by two housings 207 a and 207 b , one side of which the engaging housings 207 a and 207 b are screwed by a fastening cover 208 to ensure the fixing thereof. The details of the apparatus for supporting a monitor of the invention are illustrated below.
[0038] [0038]FIG. 3A is a disassembled view of the apparatus for supporting the monitor according to the first embodiment of the invention. The apparatus for supporting the monitor comprises a latching assembly 302 and a shaft assembly 304 coupled to a supporting arm 210 . The latching assembly 302 includes a tenon 312 , a spring 314 , and a control bar 332 . FIG. 3B is a perspective view of the tenon of FIG. 3A. In FIG. 3B, one end of the tenon 312 has a protrusive portion 344 while the other end has a conjunctive portion 342 , according to their operating functions. Between the protrusive portion 344 and the conjunctive portion 342 is the main body 346 of the tenon 312 .
[0039] The shaft assembly 304 includes a rotation control unit 306 , a shaft base 308 , a plurality of washers 310 , and a screw 318 . FIG. 3C is a front view of the rotation control unit of FIG. 3A. The rotation control unit 306 is a metallic plate with the U-shaped cuts. There are a first U-shaped cut 3061 and a second U-shaped cut 3062 formed in the edge of the rotation control unit 306 ; also a central opening 3063 is formed in the center of the rotation control unit 306 . The first U-shaped cut 3061 is created to control the rotation angle of the LCD, so as to enable the LCD to tilt in the range of 2 degrees forward and 25 degrees backward. The second U-shaped cut 3062 is created for enabling the LCD to tilt in the range of 2 degrees forward and 90 degrees backward. FIG. 3D shows the ranges of the angles of the rotation control unit of FIG. 3A.
[0040] [0040]FIG. 3E is a perspective view of the shaft base of FIG. 3A. One end of the shaft base 308 has a conjunctive portion 3081 , and a number of threads 3082 are formed on the top of the conjunctive portion 3081 . The rotation control unit 306 and the washers 310 fit onto the conjunctive portion 3081 of the shaft base 308 . Additionally, there are two threaded holes 3083 a and 3083 b on the other end of the shaft base 308 , associated with another threaded holes on the LCD base 204 , for securing the shaft base 308 on the base 204 by the use of a bolt. When the LCD 202 rotates with the base 204 (see FIG. 2), the supporting frame 210 rotates with the shaft base 308 accordingly.
[0041] Additionally, a number of washers 310 are designed for releasing the friction between the rotation control unit 306 and the shaft base 308 , and also for providing the frictional torque. FIG. 3F is a perspective view of the washers of FIG. 3A. The washers 310 illustrated in an order from left to right are: a fix washer 320 , a torque washer 322 , two spring washers 324 a and 324 b , and three torque washers 326 , 328 a , and 328 b . For achieving the objective of smooth rotation and long-term durability, seven washers are preferably used in example 1; however, the invention is not limited herein. The number and composition of the washers may be selectively varied to accommodate a wide range of LCD panel sizes, weights, and degrees of mass unbalance.
[0042] The circular holes are formed on the sidewalls of the supporting frame 210 , in which the latching assembly 302 and the shaft assembly 304 are coupled. As shown in FIG. 3A, the supporting frame 210 includes a first sidewall 220 and a second sidewall 230 . A first tenon hole 336 a and a second tenon hole 336 b are formed on the first sidewall 220 and the second sidewall 230 , respectively. A shaft hole 338 is formed next to the second tenon hole 336 b . Also, a hook 340 situated in the lower end of the second sidewall 230 projects outward. The latching assembly 302 is mounted on the supporting frame 210 through the first tenon hole 336 a and the second tenon hole 336 b . The shaft assembly 304 is mounted on the supporting frame 210 through the shaft hole 338 . The hook 340 slides along the second U-shaped cut 3062 of the rotation control unit 306 . When the hook 340 hits the risen edge of the second U-shaped cut 3062 , the supporting frame 210 stops moving, and consequently the LCD stops rotating.
[0043] In the foregoing description, the components of the apparatus for supporting a monitor, such as the washers, the tenon, the supporting frame, and the rotation control unit, are hardened by thermo-treatment. The hardened components, not easy to be aged and broken, are employed to ensure that the applied LCD can be stably rotated in frequent use.
[0044] During assembly, the conjunctive portion 3081 of the shaft base 308 is inserted through the central opening 3063 of the rotation control unit 306 , the shaft hole 338 , and the washers, and then is secured on the second sidewall 230 of the supporting frame 210 by a fastener, such as a screw 318 . It is noted that the opening of the fix washer 320 and the cross section of the conjunctive portion 3081 are not circular, but tangent to the shaft hole 338 and the openings of other washers. Next, the spring 314 slides on the conjunctive portion 342 of the tenon 312 . The tenon 312 is then mounted between the first tenon hole 336 a and the second tenon hole 336 b , wherein the protrusive portion 344 is projected beyond the second sidewall 230 .
[0045] Also, the control bar 332 , inserted through the control slot 350 of the control bracket 334 , is situated on the main body of the tenon 346 and can be moved along the control slot 350 by the user. When the control bar 322 is not pushed by an external force, the protrusive portion 344 projects beyond the second sidewall 230 and is coupled with the first U-shaped cut 3061 . When the control bar 322 is moved toward the left hand side (FIG. 3A), the protrusive portion 344 is consequently moved toward the inner of the supporting frame 210 and compresses the spring 314 . Therefore, the protrusive portion 344 can be removed from the first U-shaped cut 3061 by the movement of the control bar 332 .
[0046] Subsequently, the two housings 207 a and 207 b , which have almost symmetrical structures, are engaged together so that the supporting frame 210 and the other components mounted thereon can be fully enclosed. Then, one side of the engaging housings 207 a and 207 b are screwed by a fastening cover 208 to complete the assembly.
[0047] The following description and related drawings illustrate the operation of the apparatus for supporting a monitor according to the first embodiment of the invention. It is assumed that the LCD monitor is rotated in the range of +2 degrees (tilted forward 2 degrees from the vertical line) to −25 degrees (tilted backward 25 degrees from the vertical line), and also folded to an angle of 90 degrees.
[0048] [0048]FIG. 4A is a perspective view of the assembled apparatus for supporting the monitor according to the first embodiment of the invention, while the LCD is vertical to the base. FIG. 4B is a side view of the apparatus of FIG. 4A. The front surface 402 of the supporting frame 210 is a plane for attaching the LCD (not shown). In FIG. 4A and FIG. 4B, the front surface 402 is parallel to the LCD and y-axis, and the base of the LCD is parallel to x-axis. It is defined that the angle of rotation is 0 degree while the LCD is vertical to the base. Meanwhile, the protrusive portion 344 of the tenon 312 and the hook 340 are coupled with the first U-shaped cut 3061 and the second U-shaped cut 3062 of the rotation control unit 306 , respectively. Without application of an external force, the control bar 332 , projected beyond the control bracket 334 , stays in the right position of the control slot 350 (close to the second sidewall 230 of the supporting frame 210 ), and consequently the protrusive portion 344 projects beyond the second tenon hole 336 b . If the LCD is rotated, then the shaft base 308 and the rotation control unit 306 are not able to rotate, but the supporting frame 210 , the latching assembly 302 and the washers can rotate around the shaft base 308 ; therefore, the protrusive portion 344 and the hook 340 slide along the edges of the first U-shaped cut 3061 and the second U-shaped cut 3062 of the rotation control unit 306 , respectively.
[0049] Simply saying, when the LCD is rotated toward the direction of F1 (see FIG. 4B), the protrusive portion 344 and the hook 340 respectively slide along the edges of the first U-shaped cut 3061 and the second U-shaped cut 3062 of the rotation control unit 306 in the direction of F1. If the LCD is rotated toward the direction of F2, the protrusive portion 344 and the hook 340 are moved toward the direction of F2.
[0050] When the protrusive portion 344 hits the risen edge of the first U-shaped cut 3061 of the rotation control unit 306 , the LCD stops rotating and is positioned at an angle of 25 degrees. If the rotation of LCD from the angle of 25 degrees to 90 degrees is desired, the protrusive portion 344 must be removed from the top of the first U-shaped cut 3061 . FIG. 5A is a perspective view of the assembled apparatus for supporting the monitor of the invention, while the LCD with the retracted protrusive portion of the tenon is tilted backward to 25 degrees. FIG. 5B is a side view of the apparatus of FIG. 5A. It is clearly shown in FIG. 5A that the protrusive portion 344 is retracted away from the first U-shaped cut 3061 by moving the control bar 332 toward the second sidewall 220 . The LCD can be folded to the angle of 90 degrees; meanwhile, the protrusive portion 344 slides against the rear surface of the rotation control unit 306 .
[0051] In accordance with the description above, it is apparently indicated that the tilt angle of the LCD is determined by the sizes of the first U-shaped cut 3061 and the second U-shaped cut 3062 of the rotation control unit 306 . However, the tilt angle of the invention is not limited in the range of 2 degrees forward to 25 degrees backward, and the fold angle, to 90 degrees. According to the practical application of the invention, the size of the first U-shaped cut 3061 is substantially associated with the first angle range, and the size of the second U-shaped cut 3062 is substantially associated with the second angle range.
[0052] Additionally, the apparatus for supporting a monitor can be further designed to rotate the LCD only in the first angle range, such as 2 degrees forward to 25 degrees backward, without the 90-degree folding design. Accordingly, the latching assembly 302 can be replaced with a protruding element so that the protruding element slides along the edge of the first U-shaped cut 3061 . For example, the control bar 332 can be eliminated, or the latching assembly 302 is replaced with the protruding element, which is formed on the position of the second tenon hole 336 b on the second sidewall 230 . The protruding element could be the original protrusive portion 344 , or a protruding element integrated with the supporting frame 210 as a whole.
[0053] It has been repeatedly tested by test engineers, and demonstrated that the mechanical apparatus for supporting a monitor of the invention has better position effect than the conventional supporting apparatus. Also, the LCD equipped with the apparatus for supporting a monitor of the invention is not easy to be aged, and the durability thereof is highly increased. Additionally, the overall size of the apparatus for supporting a monitor of the invention is much smaller, so that the space for connecting the LCD and the base can be decreased.
EXAMPLE 2
[0054] In this second embodiment, the structure and components are similar to those of the first embodiment. Generally, the purpose of positioning the LCD is achieved by cooperation of a rotation control unit with cuts, a lock assembly, and a hook. The details are illustrated below.
[0055] [0055]FIG. 6A is a disassembled view of the apparatus for supporting the monitor according to the second embodiment of the invention. In the second embodiment, the apparatus for supporting a monitor comprises a supporting frame 410 , a lock assembly 502 , and a shaft assembly 504 . The lock assembly 502 includes a lock pin 512 and a couple ring 516 . FIG. 6B is a perspective view of the lock pin of FIG. 6A. One end of the lock pin 512 has a protrusive portion 544 , and the other end has a conjunctive portion 542 .
[0056] The shaft assembly 504 includes a rotation control unit 506 , a shaft base 508 , a plurality of washers 510 , and a screw 518 . FIG. 6C is a front view of the rotation control unit of FIG. 6A. The rotation control unit 506 is a metallic plate with the U-shaped cuts. There are a first U-shaped cut 5061 and a second U-shaped cut 5062 formed in the edge of the rotation control unit 506 ; also a central opening 5063 is formed in the center of the rotation control unit 506 . When the LCD is rotated backward to an angle of 25 degrees, the protrusive portion 544 of the lock pin 512 couples to the first U-shaped cut 5061 . The second U-shaped cut 5062 functions in the same manner as in the first embodiment, for rotating the LCD in the range of 2 degrees forward to 90 degrees backward. FIG. 6D shows the said angles of the rotation control unit of FIG. 6A.
[0057] Additionally, a number of washers 510 are designed for releasing the friction between the rotation control unit 506 and the shaft base 508 , and also for providing the frictional torque. In FIG. 6A, the washers 510 , illustrated in an order from left to right, are: a fix washer 520 , a rotation control washer 522 , and four spring and torque washers 524 a , 524 b , 524 c , and 524 d . For achieving the objective of smooth rotation and long-term durability, six washers are preferably used in example 2; however, the number and composition of the washers may be selectively varied to accommodate a wide range of LCD panel sizes, weights, and degrees of mass unbalance. Also, the shaft base 508 has a conjunctive portion 5081 , and the rotation control unit and the washers are mounted thereon. Also, there are threaded holes on the other end of the shaft base 508 , associated with another threaded holes on the LCD base 204 , for securing the shaft base 508 on the base 204 by the use of a bolt.
[0058] The supporting frame 410 includes a first sidewall 420 and a second sidewall 430 . A first lock pin hole (not shown) and a second lock pin hole 536 b are formed on the first sidewall 420 and the second sidewall 430 , respectively. Both lock pin holes are provided for mounting the lock assembly 502 . Also, a shaft hole 538 is formed next to the second lock pin hole 536 b.
[0059] During assembly, the conjunctive portion 5081 of the shaft base 508 is inserted through the central opening 5063 of the rotation control unit 506 , the shaft hole 538 , the washers, and then secured on the second sidewall 430 of the supporting frame 410 by a screw 518 . It is noted that the opening of the fix washer 520 and the cross section of the conjunctive portion 5081 are not circular, but tangent to the shaft hole 538 and the openings of other washers. Next, the spring 514 slides on the conjunctive portion 542 of the lock pin 512 . The lock pin 512 is then mounted between the first lock pin hole and the second lock pin hole 536 b , and secured by a couple ring 516 such as a E type ring. After assembly, the protrusive portion 544 projects beyond the second sidewall 430 by the elastic force of the spring 514 . Subsequently, the two housings 207 a and 207 b and the fastening cover 208 are engaged together so as to fully enclose the supporting frame 210 and the other components.
[0060] When the supporting frame 410 is rotated, the protrusive portion 544 of the lock pin 512 moves against the back surface of the rotation control unit 506 . While the supporting frame 410 is rotated to a predetermined angle; for example, in a 25-degree tilt backward from the vertical central line, the protrusive portion 544 couples to the first U-shaped cut 5061 . Also, a hook 540 situated in the lower edge of the rotation control unit 522 . The hook 540 slides along the second U-shaped cut 5062 of the rotation control unit 506 , and stops moving when the hook 540 hits the risen edge of the second U-shaped cut 5062 , such as point e or point f shown in FIG. 6C. Additionally, the fix washer 520 of FIG. 6A further has a clasp 560 , which the clasp 560 is coupled to the fix cut 550 (FIG. 6C) on the edge of the rotation control unit 506 .
[0061] [0061]FIG. 7A is a perspective view of the assembled apparatus for supporting the monitor according to the second embodiment of the invention, while the LCD is vertical to the base. FIG. 7B is a side view of the apparatus of FIG. 7A. The front surface 602 of the supporting frame 410 is a plane for attaching the LCD (not shown in FIG. 7B). In FIG. 7B, the front surface 602 is parallel to the LCD and y-axis, and the base, of the LCD is parallel to x-axis. While the LCD is vertical to the base, the protrusive portion 544 of the lock pin 512 is against the back surface of the rotation control unit 506 , and the spring 514 is therefore compressed, as shown in FIG. 7A. Also, the hook 540 actively couples to the second U-shaped cut 5062 of the rotation control unit 506 . Simply saying, if the LCD is rotated from the vertical state to 25 degree backward, the protrusive portion 544 slides against the back surface of the rotation control unit 506 , while the hook 540 slides from the point e to point f (FIG. 6C) of the second U-shaped cut 5062 .
[0062] [0062]FIG. 8A is a perspective view of the assembled apparatus for supporting the monitor according to the second embodiment of the invention, while the LCD is tilted backward to 25 degrees. FIG. 8B is a side view of the apparatus of FIG. 8A. When the LCD is rotated backward to a predetermined angle such as 25 degrees, the protrusive portion 544 exactly couples to the first U-shaped cut 5061 . Meanwhile, the elastic recovery force of the spring 514 acts on the lock pin 512 , so that the lock pin 512 is projected beyond the first U-shaped cut 5061 , and the rotation of LCD is stopped. Since the lock pin 512 is positioned by a couple ring 516 , the lock pin 512 does not drop out of the first U-shaped cut 5061 . If folding the LCD to 90 degrees is desired, the pressure between the protrusive portion 544 and the rotation control unit 506 is overcome only by applying an external force. When the protrusive portion 544 is uncoupled from the first U-shaped cut 5061 , the LCD can be further rotated and the spring 514 is compressed again.
[0063] In practical application, the size and position of the U-shaped cuts of the invention can be selectively varied to accommodate the rotation angle range. For example, if the rotation angle range of LCD is set up as 10 degrees forward to 30 degrees backward, the first U-shaped cut 5061 is shifted to the associated position.
[0064] From the above descriptions of the operation of the apparatus for supporting a monitor of the first and second embodiments, it is apparent that the rotation control unit is a key feature of the invention. The rotation angle of the LCD depends on the size of the U-shaped cuts of the rotation control unit. Although the rotation angle range of 2 degrees forward to 25 degrees backward is taken for illustration, the rotation angle of the invention is not limited herein.
[0065] According to the aforementioned descriptions, the apparatus for supporting a monitor has several advantages. The mechanical apparatus for supporting a monitor of the invention, using a rotation control unit and a tenon or lock pin, has better a position effect than the conventional supporting apparatus. The LCD equipped with the apparatus for supporting a monitor of the invention is not easy to be aged, and the durability thereof is highly increased. The overall size of the apparatus for supporting a monitor of the invention is reduced, so that the space for connecting the LCD and the base is smaller.
[0066] While the invention has been described by way of examples and in terms of preferred embodiments, it is to be understood that the invention is not limited thereto. On the contrary, it is intended to cover various modifications and similar arrangements and procedures, and the scope of the appended claims therefore should be accorded the broadest interpretation so as to encompass all such modifications and similar arrangements and procedures. | A hinge assembly for pivotably connecting the display portion and the body portion of the portable computer comprises a first fastening portion for attaching to the display portion, a second fastening portion for attaching to the body portion, and a pivot portion for pivotably connecting the first fastening portion with the second fastening portion. The second fastening portion also has a first support arm for horizontally inserting into the insertion hole. The cables, for transmitting signals and power extending from the display portion, are electrically connected through connectors to the cable connection region. The cable connect region is formed on the rear wall or bottom wall of the body portion. The hinge assembly of the invention greatly reduces the extraordinary sound resulting from the rotation of the display portion. Also, some covering components can be eliminated to make the assembly much easier. | 4 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] Pursuant to 35 USC § 119(e), this application claims benefit of prior U.S. provisional application 60/393,043, filed Jun. 28, 2002.
FIELD OF INVENTION
[0002] This invention relates to sewage and wastewater treatment and in particular to biological treatment of wastewater using a sequencing batch reactor configuration.
BACKGROUND OF INVENTION
[0003] While very basic technologies such as land & grass filtration, septic tanks/soak-away pit and stabilization ponds are still widely and appropriately used in many developing countries, these technologies are only able to meet non-stringent discharge standards. More advanced technologies must be used to meet increasingly more stringent effluent discharge requirements. These advanced technologies are based on the use of microbial activity under aerobic and/or anaerobic and/or anoxic treatment conditions to meet different and multiple treatment objectives. Treatment objectives range from the removal of simple organics (biological oxygen demand [BOD], chemical oxygen demand [COD], total organic carbon [TOC]) and total suspended solids [TSS] removal to the meeting of stringent nutrient (nitrogen [N], phosphorus [P]) discharge standards and the removal of complex organics and/or toxic contaminants.
[0004] Biological wastewater treatment technologies may be classified using a number of categories that relate to the presentation of the biomass, flow, operation, configuration. etc. of the treatment process.
[0005] These categories include, but are not limited to:
[0006] Flow: dispensing of the wastewater into, out of, and within the system, which may be a continuous or intermittent process;
[0007] Operation: the control and operation of the system, which may be continuous or intermittent for the operational parameters, e.g. flow, volume, aeration, temperature, pH, mixing, recycling, excess sludge wastage rate, etc.
[0008] Biomass: micro-organisms that are used for the removal of waste material. The biomass may be attached as a biofilm on the surface of a carrier or cultured in a suspension generally known as activated sludge;
[0009] Sludge: used to refer to the different types of biomass in the reactor, e.g. activated sludge, waste sludge, nitrifying sludge. For this invention, the term “sludge” is used with emphasis on its uniqueness in achieving treatment objective(s) and is in the form of biofilm when it is fixed on a carrier, and/or activated sludge when it is suspended in the liquid.
[0010] Carrier: support medium (numerous types) used for attachment of a film of biomass. The carrier may be made of different materials (examples include but are not limited to wood chips, gravel, ceramics, alloy, plastics, rubber, recycled tyres), and may be mobile (i.e. freely movable within the tank) or fixed (i.e. immobilized or attached to the tank with limited movement)
[0011] Tank: major physical structure(s) for containment of liquid. A tank may also have the same meaning as reactor or bioreactor. Reactors may be sub-divided into tanks, and the tanks into sub-tanks. Other similar terms such as “basin”, etc. will not be used herein for clarity.
[0012] Stage: the predominant biochemical or bioreaction function in the pollutant removal process, for example removal of carbonaceous, nitrogenous (nitrification function and/or denitrification function, etc.) or phosphorous compounds. In any system, there may be different tanks or tanks/sub-tanks that are used to perform different stages of pollutant removal. These are typically configured and operated differently from the other stage(s) to achieve the predominant function.
[0013] Reactor: Tanks of the wastewater treatment plant, which may include chemical, physical, biological, etc. processes.
[0014] Clarification: process wherein the biomass is separated from the water to produce the final effluent, e.g. using secondary clarifier, SBR during settling phase, etc.
[0015] Bio-selector: optional initial stage where the biomass first contacts the wastewater wherein conditions of initial high food: microorganism ratio (F/M) or floc-load are established to enhance the biomass characteristics, particularly minimization of bulking and foaming bacteria. Many types (e.g. aerobic, anoxic, anaerobic or their combination) and designs are available.
[0016] Each combination has various advantages and disadvantages that may make them more suitable, space-efficient and cost-effective for one or another application.
[0017] Current Available Technologies: Aerobic (Full or Partial) Treatment Processes Activated Sludge Processes
[0018] Activated sludge (AS) processes are the currently most widely used treatment systems. They are capable of meeting very high effluent BOD/COD and nutrient discharge standards. Wastewater is mixed with suspended biomass, and the resulting mixed liquor typically flows continuously through the treatment system. Thus, the AS is subjected to different conditions. The pollutants are converted to solids (biomass or sludge) and/or gas with the production of water through their metabolic processes and under the following typical conditions as regards oxygen species:
[0019] 1. Organic removal only: under fully aerobic conditions;
[0020] 2. Organic and nitrogen removal only: under aerobic and anoxic conditions;
[0021] 3. Organic, nitrogen and phosphorus removal: under aerobic, anoxic and anaerobic conditions.
[0022] Following biological wastewater treatment the biomass must be separated from the wastewater so that treated effluent may be discharged. This separation is normally done using gravity sedimentation or forced clarification. To facilitate the separation process, the operating mixed liquor suspended solids (MLSS) concentration is typically restricted to <3,500 mg/L. The excess sludge produced, as the end product of biological wastewater treatment, requires further treatment, usually digestion and/or dewatering.
[0023] Growth of slow growing and sensitive bacteria such as nitrifiers and those required to break down complex refractory organics is a rate-limiting step that requires long operating sludge ages to achieve the desired effluent quality. The resultant low food:microorganism ratio (F/M) results in large volume bioreactor tanks. For nutrient removal, additional anaerobic/anoxic tanks must be added.
[0024] The secondary clarifiers also have large volume requirements, particularly if the operating sludge age is long, which typically results in poorly settling sludge. Handling of the excess sludge also requires substantial capital investment and higher operating costs. The tanks and clarifiers also require large areas for their construction. In highly populated regions, land limitations restrict the feasibility of using conventional activated sludge with clarifier systems.
[0025] Sequencing Batch Reactor (SBR) Activated Sludge Processes
[0026] To eliminate separate secondary clarification units, fill-and-draw or batch treatment systems such as the Sequencing Batch Reactor (SBR) were revived. In these SBR systems, which use activated sludge and cyclic time-oriented ON/OFF operation, the entire treatment tank is also used as a clarifier. A high degree of process control of all unit operations enables high treatment standards to be met.
[0027] In the second generation of SBR technology (SBR2), floc-load controlled bio-selector and separate anaerobic/anoxic tanks, similar to those of the conventional continuous flow AS systems, were introduced to provide filamentous bulking and foaming control and better nutrient removal, respectively. However, the SBR systems are still hydraulically limited with resultant large reactor tank(s) by the need for long operating sludge ages as restricted by the large unaerated mass fraction of typically 50% which result in large MLSS requirements and, consequently, a long time for settling of biomass and decant of treated effluent. Typical hydraulic retention time (HRT) ranges from 15-24 hours. Furthermore, during part of each cycle the decanters and the aeration diffusers are inactive giving, in effect, a fraction of ‘inactive capital’.
[0028] Bio Film Processes
[0029] Biofilm systems are attached biomass systems that use a solid support medium or carrier(s) on which the biomass grows. Excess biofilms falls off the carriers such that a secondary clarifier (small) is still needed. Conventional biofilm systems include trickling filters, rotating biological contactors (RBC) and submerged aerated filters (SAF). These can be compact systems, but suffer from poor control of reaction conditions, problems with mixing and oxygen transfer, slow start-up and recovery times from upset, clogging, and a very complex ecology. Newer systems include the biological aerated filters (BAF), which rely on backwash of the fixed media to remove the excess biofilm.
[0030] Hybrid Processes—Combined Biofilm and Activated Sludge
[0031] In these relatively recent processes, both carriers (fixed or mobile) and activated sludge are in the same treatment system. Fixed carrier AS systems, such as activated trickling filters and aerated RBC systems, are used mainly for high strength wastewater treatment. They consist of fixed carrier biofilm systems with a downstream AS system to meet the required effluent discharge standards. In contrast, mobile biofilm carriers are incorporated in AS systems to treat low strength wastewaters for nitrification with and without denitrification. These technologies include moving bed bioreactor (MBBR) and sequencing biofilm batch reactor (SBBR), which consist of simply adding carriers to the reactor tank.
[0032] These hybrid processes offer advantages including a more compact footprint (smaller process volume) due to the independence of the HRT from the operating sludge age. However, these hybrid systems also suffer from some of the same problems as the biofilm technologies, particularly, poor control of reaction conditions.
[0033] Current Available Technologies: Anaerobic Treatment Processes
[0034] Anaerobic treatment is a process that involves (1) the biological hydrolysis of particulates in the wastewater to soluble organic matter followed by conversion of soluble organics to short chain organic acids and (2) the production of gas (methane and carbon dioxide), all in the absence of oxygen.
[0035] Anaerobic treatment is suitable to treat high strength industrial wastewaters and side-stream(s) of large municipal sewage treatment works. However, meeting typical effluent discharge requirements is difficult and there is no nutrient removal capability. A downstream aerobic treatment is sometimes used. The methane produced may be used to generate energy.
[0036] Low technology systems (low reaction rate/large volume) have historically been used for a range of applications. Typical current-day applications include digestion of sludges and solid waste, and pond treatment. Two-stage high-rate anaerobic processes have been developed in recent years with higher reaction rates and low HRT (e.g. one day). High-rate treatment is widely used for high strength soluble organics industrial waste, and occasionally for the treatment of sewage.
[0037] In the first stage, incoming organic carbon is converted to small chain organic acids in a continuously fed, stirred-tank reactor. In the second stage, the acids are converted to methane and carbon dioxide gas. The organisms generally grow together in flocs or on artificial media, and are relatively slow growing and pH sensitive. Operating temperatures may be either in the thermophilic or mesophilic range.
[0038] Many anaerobic reactor designs are available, including Upflow Anaerobic Sludge Blanket (UASB), Contact (or Internal Circulation) Reactor, Fixed Film/Bed Reactor, Hybrid, Fluidised Bed (FB) and Expanded Granular Sludge Blanket (EGSB). The main technical challenge and focus has been stability of the second stage, but little (if any) attention has been made to improvements in the first stage. A common limitation is poor control of reaction conditions.
[0039] It is therefore the object of this invention to provide a new and improved method of wastewater treatment using a new hybrid SBR technology.
SUMMARY OF INVENTION
[0040] In accordance with the object of the present invention, there is provided in one aspect a system (also referred to as the SBR3 system) for treating wastewater comprising at least one reactor. The reactor includes at least a first tank interconnected to a second tank for retaining wastewater therein and discharging wastewater therefrom. The tanks are provided with means for influence and means for effluence to allow fluid level within at least one tank to be fillable to a filled level and decantable to a lower discharged level. Independently controllable first and second means for stage generation are provided for each the first and second tank respectively. Within the tanks, carriers for growth of biomass are also provided. A controller for controlling the operation of the first and second means for stage generation is provided such that biofilm biomass suitable for one bioreaction stage is selectively grown on the carriers as a first sludge within the first tank, and biofilm biomass suitable for a second bioreaction stage is selectively grown on the carriers as a second sludge within the second tank.
[0041] The means for stage generation may be any devices or built-in design of the system that allows the desired conditions to be attained for the appropriate bioreactor functions. In the preferred embodiment, the means for stage generation comprises at least one mixer, aerator, gas generator, heater, cooler or pump or a combination thereof to control the operation parameters such as oxygen, redox (ORP), temperature, pH and fluid level for further control of stage conditions.
[0042] In one implementation, the first tank and the second tank are partitioned by a separation wall therebetween, with openings provided in the wall for the wastewater and biomass (activated sludge) or mixed liquor to flow therebetween. This allows the two tanks to act as a single SBR unit with the same fluid level achieved during the fill and decant sequences. In an alternative implementation, the wall separating the two tanks may be shorter than the side-walls of the reactor, with the means for influence provided in the first tank, and the means for effluence provided in the second tank. In such an implementation, the complete filling of the first tank will cause overflowing of the wastewater or mixed liquor into the second tank, and decanting occurs only in the second tank.
[0043] In yet another preferred embodiment, the system further includes an optional third tank and recycling means for connecting the first and/or second tanks thereto. The recycling means may be, for example, a pump and its related piping that are adapted for transferring mixed liquor from bioreaction in the first or second tanks into the third tank for the next stage of bioreaction. Alternatively, the third tank may be partitioned from the first and/or second tank by a separation wall in the same way as described above for separation between the first and second tanks.
[0044] Activated sludge biomass is also present and suspended in the mixed liquor. This activated sludge is comprised of biofilm biomass that has fallen off from the biofilm carriers of different stages, if the activated sludge is allowed to mix together. This activated sludge may enhance the functions to achieve the specified treatment objectives. However, there are reaction conditions, with and without the addition of one or more stage(s), necessary to allow a specific sludge with an enhanced function to achieve a different treatment objective(s) as different from the biofilm biomass of each individual stage(s).
[0045] According to the user's needs, an optional fourth tank may be further provided and adapted to receive wastewater or mixed liquor from the third tank for yet another stage of bioreaction, if desired. The same type of connecting means and separation wall may also be provided as described above for connection and recycling between the four tanks according to the user's requirements.
[0046] More bioreaction stage(s) and sludge(s) may be added to achieve different treatment objective(s).
[0047] In another aspect of the present invention, a method is provided for treating wastewater using at least one reactor containing at least a first tank and a second tank interconnected therebetween. The tanks are provided with carriers for growth of biomass thereon. This method includes the steps of dispensing wastewater into the first and, optionally, second tanks; controlling the operating conditions separately such that a first condition is created for growth of a first biomass attached on the carriers as a first sludge suitable for a first bioreaction stage within the first tank, and a second condition is created for growth of a second biomass attached on the carriers as a second sludge suitable for a second bioreaction stage within the second tank; and decanting the wastewater in at least one tank after treatment therein. The operating conditions to be controlled depends on the user's needs, and may include, among other parameters the oxygen, pH. temperature, fluid level and hydraulic of the wastewater in the first and second tanks
[0048] In one implementation of the method, the first stage is anoxic denitrification, and the first condition is pollutant removal without aeration, whereas the second stage is aerobic nitrification, and the second condition is produced, for example, by aerating the carriers containing biomass to produce sufficient oxygen content in the second tank. In this regard, the first or second sludge together with the carriers on which they are attached is preferably denser than the mixed liquor used for treatment thereof; and the first or second condition is produced by varying the SBR operating conditions, for example, by control of aeration including intermittent aeration to cause intermittent suspension of the carriers in the first or second tank.
[0049] In another implementation, the reactor further includes a third tank, and the method further comprises transferring mixed liquor generated after bioreaction in the first or second tank into the third tank. As a further optional implementation, the reactor may include a fourth tank, and the method further comprises transferring mixed liquor from the third tank into the fourth tank. The bioreaction that may be carried out within the third and fourth tanks include, for example, carbon or phosphorus removal. Some useful combinations are described generally below, and further details are elaborated in the detailed description. To distinguish between existing SBR systems and those of the present invention, the term “SBR3” is also used below to refer to systems designed according to the present invention.
[0050] The SBR3 utilises a multi-stage and multi-tank configuration incorporating fixed and/or mobile biofilm carriers, and with or without a bio-selector. At least one of the tanks must be operated in an SBR mode (i.e. with defined time-oriented cycle operation, variable-volume operation with preset Top & Bottom water levels, etc). Also, the SBR3 must have at least two stages and two tanks. The operational parameters will be optimized in the tanks to produce highly efficient sludges, which is key to the improved efficiency of the SBR3.
[0051] The stage and the sludge which is generally associated with it are named herein according to their main functional role, as follows:
[0052] For Aerobic (Full or Partially Aerobic)
BS RC, DN, P and enhancement of sludge settleability which is based on the minimization of the bulking and foaming filamentus bacteria N Nitrification DN Denitrification P Phosphorus removal RC Readily bio-degradable carbon removal SC Slowly bio-degradable carbon removal
[0053] For Anaerobic (Partially Anaerobic) Treatment:
HP Hydrolysis AC Acid formation MP Methane producing
[0054] This new system combines the advantages of the prior art SBR, AS and biofilm systems to provide a compact, flexible, stable, robust, shock-resistant system that can provide a high quality effluent that is cost and space effective. SBR features such as compact modular configuration, and a high degree of process control are enhanced while the robust nature and reduced clarification requirements of the biofilm systems are incorporated.
[0055] The SBR3 will be capable of meeting any one or a selected number of biological treatment objectives (i.e. biochemical or functional stages), depending on how the system is operated and/or configured. The SBR3 system can be tailored to exactly meet the treatment requirements, which may include removal of 1) total suspended solids (TSS) and organics (particularly the slowly biodegradable refractory organics), 2) TSS, organics, and nitrogen species (N), 3) TSS, organics, N and phosphorus species (P), etc. The SBR3 may be applied to either intermittent or continuous influent flow patterns.
[0056] For example, the first tank in the SBR3 multi-sludge and multi-stage process may contain high rate organic degrading (RC) and/or denitrifying (DN) sludge(s) in the carrier (fixed or mobile) and/or in the mixed liquor, where anaerobic/anoxic/aerobic conditions may be maintained according to the process operation. Slow growing bacteria such as nitrifiers, which are rate limiting in AS systems, attach to the carriers in the subsequent SBR-mode reaction tank where aerobic conditions are plentiful. This biofilm is the nitrification (N) sludge. Consequently, the MLSS concentration can be optimized/minimized allowing rapid settlement and removal of effluent for maximum hydraulic capacity.
[0057] For aerobic treatment, the carriers also allow less costly coarse bubble diffusers and jet aerators to be used with similar oxygen transfer efficiency to that of the membrane fine-bubble diffusers. The ability of the system to simultaneously have both aerobic and anoxic conditions present at the same time may allow simultaneous nitrification-denitrification to be achieved and N removal to be promoted and increased.
[0058] Another flexibility is that under peak flow conditions, the tank for effluence will not be aerated or mixed and will be operated for continuous settling/clarification and discharge only.
[0059] The process configuration and modes of operation for the SBR3 depend upon the characteristics of the wastewater to be treated and the effluent discharge requirements. The following is a list of illustrative applications of the SBR3 invention for specified wastewater treatment objectives. Note that the terms “aerobic”, “anoxic”, and “anaerobic” refer only to the predominant condition of a stage and do not exclude the occurrence of the other conditions (e.g. SBR mode typically has some un-aerated time period for settle/decant).
[0060] Aerobic (Full or Partially Aerobic) Treatment
[0061] 1. Two-Sludge SBR3 Processes for Organics & Suspended Solids Removal Only
[0062] a) Two-stage aerobic—aerobic process (illustrated in Case 1 in the following section)
[0063] b) Three-stage aerobic—aerobic-aerobic process
[0064] An example for the abovementioned configuration is one stage for readily biodegradable organics removal (Stage RC) and two stages for two different types of slowly biodegradable organics removal (Stages SC1 and SC2), with RC sludge cultivated as a biofilm on the fixed or intermittently suspended carriers in Stage RC (main role: readily biodegradable organics removal) and the SC sludges found as the biofilms on the suspended carriers in Stages SC1 and SC2 (main role: two different types of slowly biodegradable organics removal).
[0065] 2. Two-Sludge SBR3 Processes for Organics-Suspended Solids-Nitrogen Removal Only
[0066] a) Two-stage alternating anoxic/aerobic-anoxic/aerobic process (illustrated in Case 2 in the following section)
[0067] b) Two-stage alternating anoxic/aerobic-aerobic process
[0068] c) Two-stage anoxic-aerobic process
[0069] An example for the abovementioned configuration is one stage for nitrification (Stage N) and one stage for denitrification (Stage DN), with DN sludge cultivated as a biofilm on the fixed carriers in Stage DN (main role: denitrification) and the N sludge found as the biofilm on the suspended carriers in Stage N (main role: nitrification)
[0070] d) Two-stage aerobic-anoxic process
[0071] An example for the abovementioned configuration is one stage for partial nitrification, ie. Nitritation, conversion of NH 3 —N to NO 2 —N (Stage N) and denitrification (Stage DN) with either ammonium or external carbon addition, with DN sludge cultivated as a biolfilm on the fixed carriers in Stage DN (main role: denitrification) and the N sludge found as the biofilm on the suspended carriers in Stage N (main role: nitrification)
[0072] 3. Two-Sludge to Three-Sludge SBR3 Processes for Organics-Suspended Solids-Phosphorus Removal and Nitrification Only
[0073] a) Two-stage alternating anaerobic/aerobic-aerobic process
[0074] b) Three-stage anaerobic-aerobic-aerobic process
[0075] An example for the abovementioned configuration is one stage for nitrification (Stage N) and for phosphorus removal (Stages P 1 and P 2 ), with N sludge cultivated as a biofilm on the suspended carriers in Stage N (main role: nitrification) and the P sludge found as the biofilm on the suspended carriers or mixed liquor (the activated P sludge) in Stages P 1 and P 2 . The activated P sludge, which is suspended and flowing through Stages P 1 and P 2 only or all the stages (main role: Phosphorus removal by cyclic anaerobic phosphorus release and aerobic uptake)
[0076] 4. Two-, Three- and Multi-Sludge SBR3 Processes for Organics-Suspended Solids-Phosphorus and Nitrogen Removal
[0077] a) Two-stage alternating anaerobic/anoxic/aerobic-aerobic
[0078] b) Two-stage alternating anaerobic/anoxic/aerobic-anoxic/aerobic
[0079] c) Three-stage anaerobic-anoxic-aerobic process (illustrated in Case 3 in the following section)
[0080] d) Three-stage alternating anaerobic/anoxic-aerobic-aerobic process
[0081] e) Three-stage alternating anaerobic/aerobic-anoxic/aerobic-aerobic process
[0082] f) Three-stage alternating anaerobic/anoxic-anoxic/aerobic-aerobic process
[0083] g) Three-stage alternating anaerobic/anoxic-anoxic/aerobic-anoxic/aerobic process
[0084] h) Three-stage alternating anaerobic/anoxic/aerobic-anoxic/aerobic-aerobic process
[0085] i) Three-stage alternating anaerobic/anoxic/aerobic-anoxic/aerobic-anoxic/aerobic process
[0086] An example for the abovementioned configuration is the same as any one of the above two-sludge SBR3 processes for organics-suspended solids-nitrogen removal except that a third stage (Stage P) was added for phosphorus removal, with the third P sludge either growing on the carriers as a biofilm or consisting of the activated P sludge, which is suspended and flowing through all of the tanks (main role: phosphorus removal by cyclic anaerobic phosphorus release and anoxic/aerobic uptake)
[0087] Anaerobic (Fully Anaerobic) Treatment
[0088] 1. Two-, Three- and Multi-Sludge SBR3 Processes for Organics-Suspended Solids Removal and Methane Production
[0089] a) Two-stage anaerobic-anaerobic process
[0090] An example for the abovementioned configuration is one stage for hydrolysis of particulate organics and production of short-chain organic acids (Stage HP-AC) and methane production (Stage MP), with HP-AC sludge cultivated as a biofilm on the intermittently suspended carriers in Stage HP-AC (main role: hydrolysis of particulate organics and production of short-chain organic acids) and the MP sludge found as the biofilm on the suspended carriers or mixed liquor in Stage MP (main role: methane production)
[0091] b) Three-stage anaerobic-anaerobic-anaerobic process (illustrated in Case 4 in the following section)
[0092] An example for the abovementioned configuration is one stage for hydrolysis of particulate organics (Stage HP) and production of short-chain organic acids (Stage AC) and methane production (Stage MP), with HP sludge cultivated as a biofilm on the intermittently suspended carriers in Stage HP (main role: hydrolysis of particulate organics), AC sludge cultivated as a biofilm on the intermittently suspended fixed carriers in Stage AC (main role: production of short-chain organic acids) and the MP sludge found as the biofilm on the suspended carriers or mixed liquor in Stage MP (main role: methane production)
[0093] Using the high level of controllability of the present invention, wastewater containing different types of pollutants may be removed effectively, efficiently and inexpensively.
BRIEF DESCRIPTION OF THE FIGURES
[0094] [0094]FIG. 1 is a drawing to illustrate a system according to one aspect of the present invention.
[0095] [0095]FIG. 2 is a drawing to illustrate a system according to another aspect of the present invention.
[0096] [0096]FIG. 3 is a drawing to illustrate a system according to another aspect of the present invention.
[0097] [0097]FIG. 4 is a drawing to illustrate a system according to another aspect of the present invention.
[0098] [0098]FIG. 5 is a drawing to illustrate a system according to another aspect of the present invention.
[0099] [0099]FIG. 6 is a drawing to illustrate a system according to another aspect of the present invention.
[0100] [0100]FIGS. 7A & 7B are drawings to illustrate the SBR cycle sequence of a two-stage two-sludge aerobic-aerobic SBR3 process using the system shown in FIG. 1.
[0101] [0101]FIGS. 8A & 8B are drawings to illustrate the SBR cycle sequence of a two-stage two-sludge anoxic-aerobic SBR3 process using the system shown in FIG. 2.
[0102] [0102]FIG. 8C is a table to list the data of the average influent characteristics of STW site#1 during a 5-day period.
[0103] [0103]FIG. 8D is a table to list the data of the average effluent characteristics of SBR3 at STW site#1 during a 5-day period.
[0104] [0104]FIG. 8E is a table to list the data of the average effluent characteristics of conventional SBR at STW site#1 during a 5-day period.
[0105] [0105]FIG. 8F is a table to list the data of the average influent characteristics of STW site#2 during a 5-day period.
[0106] [0106]FIG. 8G is a table to list the data of the average effluent characteristics of SBR3 at STW site#2 during a 5-day period.
[0107] [0107]FIG. 8H is a table to list the data of the average effluent characteristics of conventional SBR at STW site#2 during a 5-day period.
[0108] [0108]FIG. 8I is a diagram to show the data of the daily effluent nitrogen concentration obtained from operating the SBR3 at STW site#1 for 66 days.
[0109] [0109]FIG. 8J is a diagram to show the data of the daily effluent nitrogen concentration obtained from operating the SBR3 at STW site#2 for 78 days.
[0110] [0110]FIG. 8K is a diagram to show the data of the daily effluent nitrogen and phosphorus concentrations obtained from operating the SBR3 at STW site#2 for 93 days.
[0111] [0111]FIGS. 9A & 9B are drawings to illustrate the SBR cycle sequence of a three-stage three-sludge anaerobic-anoxic-aerobic SBR3 process using the system shown in FIG. 4.
[0112] [0112]FIGS. 10A & 10B are drawings to illustrate the SBR cycle sequence of a three-stage three-sludge anaerobic-anaerobic-anaerobic SBR3 process using the system shown in FIG. 6.
DETAILED DESCRIPTION OF THE INVENTION
[0113] 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 structural and functional details disclosed herein are not to be construed as limiting, but merely 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 structure. For ease of description, the influent wastewater of all the systems is indicated as I, the air is indicated as A, and the effluent is indicated as E, and waste sludge is indicated as S in all the drawings without further explanation.
[0114] Referring to FIG. 1, the first embodiment exemplifying the present invention shows a system 110 a with three tanks 114 , 118 and 122 hydraulically interconnected together through openings in separation walls 112 a and 112 b . Tank 114 acts as an optional bio-selector for the selection of the desired floc-forming micro-organisms. To provide aeration, air may be introduced through coarse bubble diffusers 116 through an aeration supply system 116 a to provide for mixing and aeration for tanks 118 and 122 . Optional intermittent aeration can also be provided by the same system 116 to bio-selector 114 . Tank 118 contains sludge suitable for one bioreaction stage selectively grown on carriers 120 . The carriers 120 are mobile carriers but may be allowed to remain settled at the bottom of the tank 118 by not activating the coarse bubble diffusers 116 and the aeration supply system 116 a to cause mixing therein provided in the tank. Tank 122 contains second sludge suitable for another bioreaction stage selectively grown on the mobile carriers 124 . Tank 114 receives the influent wastewater via influent system 115 and may also receive returned mixed liquor from tank 122 through recycle system 128 . A device 126 to remove supernatant for effluent is provided in tank 122 .
[0115] [0115]FIG. 2 shows another embodiment exemplifying the present invention with the same configuration as FIG. 1 except in system 210 b the mixed liquor is recycled from tank 222 to tanks 214 and 218 via recycle system 230 .
[0116] Referring to FIG. 3, the third embodiment exemplifying the present invention shows a system 310 c with four tanks 332 , 334 , 336 and 338 hydraulically interconnected together through openings in separation walls 312 c , 312 d and 312 e . Tank 332 acts as a bio-selector for the selection of the desired floc-forming micro-organisms with no aeration and mixing provided. Tank 334 contains sludge suitable for one bioreaction stage selectively grown on carriers 320 . Tanks 336 and 338 contain the second sludge suitable for another bioreaction stage selectively grown on the mobile carriers 324 and may be allowed to set up different conditions and parameters, e.g. the volume percent of carriers, in each individual tank for the pilot purpose. Tank 332 receives the influent wastewater via influent system 315 and may also receive returned mixed liquor from tank 338 through a recycle system 340 . The mixed liquor may also be recycled to tank 334 through the same system 340 . To provide aeration, air may be introduced through coarse bubble diffusers 316 through the aeration supply system 316 a to provide for mixing and aeration for tanks 334 , 336 and 338 . A variable-volume decanting device 342 is provided in tank 338 . A device 343 a to remove supernatant for effluent is also provided in tank 338 .
[0117] [0117]FIG. 4 shows another embodiment of the present invention of a system 410 d with four tanks 444 , 446 , 448 and 450 hydraulically interconnected together through openings in separation walls 412 f , 412 g and 412 h . In this implementation, there are no carriers in tanks 444 and 446 for retaining sludge selectively for one bioreaction. Instead, the first sludge is the activated sludge in all the tanks providing cyclic bioreactions, and the first stage is particularly associated with the tanks 444 and 446 . Tank 448 contains the second sludge for another bioreaction stage selectively grown on mobile carriers 420 . Tank 450 contains the third sludge for the third bioreaction stage selectively grown on the mobile carriers 424 . Tanks 444 and 446 receive the influent waste water via influent system 415 b . Tanks 444 and 448 may also receive returned mixed liquor from tank 450 through a recycling system 452 . The mixed liquor may also be recycled from tank 448 to tank 444 through an optional recycling system 453 . To provide aeration, air may be introduced through coarse bubble diffusers 416 through the aeration supply system 416 a to provide for mixing and aeration for tanks 444 , 446 , 448 and 450 . A device 426 to remove supernatant for effluent is provided in tank 450 .
[0118] [0118]FIG. 5 shows another embodiment of the present invention of a system 510 e with six tanks 554 , 556 , 558 , 560 , 562 and 564 hydraulically interconnected together through openings in separation walls 512 i , 512 j , 512 k , 512 l and 512 m . Different conditions and parameters are allowed to be set up in different tanks for pilot purpose. There are no carriers in tanks 554 and 556 for retaining sludge selectively and no aeration or mixing is provided. Instead, the activated sludges flowing through all of the tanks is the first sludge providing cyclic bioreactions, and the first stage is particularly associated with the tanks 554 and 556 . Tanks 558 and 560 contain the second sludge for another bioreaction stage selectively grown on the mobile carriers 520 . Tanks 562 and 564 contain the third sludge for the third bioreaction stage on the mobile carriers 524 . Tanks 554 and 556 receive the influent wastewater via influent system 515 c . Tanks 554 and 558 may also receive returned mixed liquor from tank 564 through a recycling system 566 . The mixed liquor may also be recycled from tank 560 to tank 554 through another recycling system 568 . To provide aeration, air may be introduced through coarse bubble diffusers 516 through the aeration supply system 516 a to provide for mixing and aeration for tanks 558 , 560 , 562 and 564 . A variable-volume decanting device 542 is provided in tank 564 . A device 543 b to remove supernatant for effluent is provided in tank 564 .
[0119] [0119]FIG. 6 shows another embodiment of the present invention showing system 617 . Three closed tanks 601 , 602 and 603 are hydraulically interconnected. A wall 614 separates first tanks 601 and second tank 602 , while a wall 615 separates the second and third tanks 602 and 603 . An influent system 613 connects to the first tank 601 . Carriers 609 , 610 and 611 are provided in tanks 601 , 602 , and 603 , respectively. Mixing devices 605 are placed at the bottom of the three tanks. A separation mesh 606 is disposed near the bottom of the tank horizontally above the mixing devices in all the three tanks. The tanks 601 , 602 , and 603 are provided with covers 618 , 619 and 620 respectively. A first recycle system 604 is provided and connects tank 603 with tanks 602 and 601 . A second recycle system 612 is provided and connects tank 601 with tank 602 . A decanting device 616 is provided inside tank 603 . Means for collecting the gas is provided by a device 608 .
[0120] The influent system 613 carries wastewater into the first tank 601 . The influent wastewater flows from tank 601 to the second and third tanks 602 and 603 through the openings in separation walls 614 and 615 . The movements of carriers 609 , 610 and 611 within their respective tanks are controlled by controlling the operation of the mixing devices 605 , e.g. intermittent mixing. The first recycle system 604 is used to return the mixed liquor from the third tank 603 to the first tank 601 and the second tank 602 respectively. The second recycle system 612 is used to return mixed liquor from the second tank 602 to the first tank 601 . The decanting device 616 in the third tank 603 is used to remove supernatant for effluent. The tank covers 618 , 619 and 620 are used to maintain anaerobic conditions and to retain gasses, such as the biogas bubbles 607 produced from tank 603 . The tank cover 620 on tank 603 is connected to the biogas collection system 608 .
EXAMPLES
[0121] Four cases are described in detail for this invention:
[0122] Case 1 Two-Stage and Two-Sludge Aerobic-Aerobic Process for Organics & Suspended Solids Removal Only
[0123] One of the possible two-stage two-sludge SBR3 system configuration is illustrated in FIG. 1. The cycle sequence of the SBR3 process of case 1 is illustrated in FIGS. 7A and 7B. The cycle starts from step 7 A 1 , going through steps 7 A 2 , 7 B 1 , and 7 B 2 , and goes back to step 7 A 1 . In this process, the three tanks are used for:
[0124] (1) the first stage RC (performed in the second tank 118 ); and
[0125] (2) the second stage SC (performed in the third tank 122 ).
[0126] For the ease description of the bio-chemical processes, the following description contains reference only to the biochemical stage without further reference to the particular tanks as shown in FIG. 1, 7A or 7 B. It is understood that these processes are performed in the respective tanks.
[0127] In this case, the bioselector of RC Stage is shown as part of the RC Stage. This configuration consists of an RC Stage with RC Sludge on the mobile carriers that remain settled at the bottom of the tank when no external mixing is provided, and an SC Stage with SC Sludge on the mobile carriers. A variable-volume emptying device is provided in the SC Stage, which is illustrated in FIGS. 7A and 7B, where the wastewater level in the third tank varies. Note that in this case, the RC Stage has a constant volume, but can be designed as variable volume as well.
[0128] Either the BS (if present) or the RC Stage (assuming no BS Stage) receives influent wastewater and may also receive return mixed liquor from the SC Stage, either continuously or intermittently. The RC Stage is operated for high rate aerobic organics removal. Nitrate and/or nitrite may be either originally present in the wastewater or produced in the RC and/or the SC Stages from ammonia that may be present in the wastewater. In this case, the mixed liquor is recycled from the SC Stage to the RC Stage for denitrification when the aeration is limited or temporarily stopped. The RC Sludge is dominated by fast-growing bacteria, which are capable of degrading readily biodegradable organics. In this case, the carriers are, mobile carriers that remain near the bottom of the tank because they are slightly heavier than water, occupy 70% of the tank volume, and are provided for biomass attachment. The mobile carriers may be temporarily suspended by intermittent mixing or aeration.
[0129] Aeration may be provided by any means that can provide the proper conditions, e.g., natural gravity (e.g. waterfall), combination gravity and forced aeration, forced aeration etc. For the forced aeration, air may be introduced through coarse bubble diffusers to provide for mixing and aeration requirements. Despite the use of coarse bubble diffusers, the aeration system still approaches the efficiency of a fine bubble system due to the longer air retention time in the tank and break-up of coarse bubbles to smaller bubbles by the carriers. Up to or even more than 90% of readily biodegradable organics can be removed in the RC Stage due to the high concentration of attached biomass.
[0130] Mixed liquor in the RC Stage is in communication with mixed liquor in the SC Stage by any means of flow interconnection, e.g. overflow, channels, underflow pumping, etc. A mesh is placed at each opening to prevent any biofilm carriers from going from one stage to the other, but the activated sludge can pass through. The activated sludge containing some biofilm biomass also contributes to the treatment objectives, but is not associated with a particular stage in this case. An alternative would be to retain the mixed liquor sludge within the RC Stage instead of using carriers, and the RC Sludge would then consist of the retained activated sludge.
[0131] The SC Stage contains suspended carriers of up to 70% of the tank volume depending on the decant percentage and may be aerated using coarse bubble diffusers. This stage acts as a carbon removal polishing step and degradation of slowly biodegradable organics during the aeration sequence (SBR operation mode). Nitrification may not be an objective, but may not be avoidable. For more slowly biodegradable organics such as refractory organics, the HRT will be longer and the percentage of biofilm carriers will be higher to allow more attachment of the slow-growth bacteria on the carriers since the bacteria must be independent of the operating sludge age. Thus, the biofilm SC Sludge will have a unique composition. The SC Stage may also perform as a secondary clarifier for solids-liquid separation and return of MLSS to the RC Stage during the settle and decant sequences.
[0132] The duration of the SBR3 operating cycle can be less than two hours to up to day(s). The total HRT can be shorter than six hours. The RC Stage can employ either constant or variable volume operation while the SC Stage will be operated with variable volume mode. A bio-selector will optionally be incorporated to control biological foaming and bulking, particularly if the MLSS is high. Sludge wasting is either separately for each stage or together from the SC Stage during the settling sequence.
[0133] Case 2 Two-Stage and Two-Sludge Anoxic/Aerobic-Anoxic/Aerobic Process for Organics-Suspended Solids-Nitrogen Removal Only
[0134] One of the possible two-stage two-sludge SBR3 system configurations is illustrated in FIG. 2. Note that an optional Bioselector (BS) is shown as part of the DN Stage. The cycle sequence of the SBR3 process of case 2 is illustrated in FIGS. 8A and 8B. The cycle starts from step 8 A 1 , going through steps 8 A 2 , 8 B 1 , and 8 B 2 , and goes back to step 8 A 1 . In this process, the three tanks are used for:
[0135] (1) The first stage DN (performed in the second tank 218 );
[0136] (2) The second stage N (performed in the third tank 222 ).
[0137] For the ease description of the biochemical processes, the following description contains reference only to the biochemical stage without further reference to the particular tanks as shown in FIG. 2, 8A and 8 B. It is understood that these processes are performed in the respective tanks.
[0138] This configuration consists of a DN Stage with DN Sludge consisting of the biofilm on the carriers, and an N Stage with N Sludge consisting of the biofilm on the carriers. A variable-volume decanting device is provided in the N Stage, which is operated in SBR mode, as illustrated in FIGS. 8A and 8B, where the wastewater level in all the three tanks varies.
[0139] Similar to Case 1, the DN Stage receives influent wastewater and may also receive return mixed liquor from the N Stage, either continuously or intermittently. This DN Stage is operated for high rate continuous anoxic or alternating anoxic/aerobic denitrification and organics removal. The DN Sludge is dominated by the fast-growing denitrifying bacteria, which are also capable of degrading readily biodegradable organics. The mobile carriers remain near the bottom of the tank because they are slightly heavier than water, occupy up to 70% of the tank volume and are provided for biomass attachment. The mobile carriers may be temporarily suspended by intermittent mixing or aeration.
[0140] Aeration may be provided by any means that can provide the proper conditions, e.g. forced aeration intermittently through coarse bubble diffusers to provide for mixing and aeration requirements.
[0141] More than 90% of readily biodegradable organics can be removed in the DN Stage due to the high concentration of attached biomass. Mixed liquor in the DN Stage is in continuous communication with mixed liquor in the N Stage by any means of flow interconnection. Mixed liquor including activated sludge with sludge sloughed off from the biofilm flow on to the N Stage. A mesh is placed at each opening to prevent any carriers from going from one stage to the other.
[0142] The N Stage contains suspended carriers of up to 70% of the tank volume depending on the decant percentage and is aerated using coarse bubble diffusers. This stage operates with alternating anoxic/aerobic conditions (SBR operation mode) and acts as a nitrification and carbon removal polishing step and degradation of slowly biodegradable organics during the aeration sequence. For more slowly biodegradable organics such as refractory organics and/or wastewater containing nitrification inhibition substances, the HRT will be longer and the percentage of biofilm carriers will be higher to allow more slow-growth bacteria on the carriers for refractory organics degradation and slow-growth nitrifiers, since the bacteria must be independent of the operating sludge age. Thus, the biofilm N Sludge will have a unique composition. The N Stage may also perform as a secondary clarifier for solids-liquid separation and return of nitrified mixed liquor and MLSS to the DN Stage during the selected reaction sequences.
[0143] The duration of the SBR3 operating cycle can be less than two hours to up to twenty-four hours. The total HRT can be shorter than six hours. The DN Stage employs variable volume operation while the N Stage will be operated with variable volume mode A bio-selector will optionally be incorporated to control biological foaming and bulking if the MLSS is high. Sludge wasting is either separately for each sludge stage or together from the N Stage during the settling sequence.
[0144] Case 2 Experimental Data
[0145] Two fully automatic PLC controlled SBR pilot-scale reactors were built including an on-line wastewater sampling, monitoring and control system. The SBR3 included biofilm carriers with configuration as shown in FIG. 3 and the “conventional SBR” was identical to the SBR3 except that it had no biofilm carriers and was used as a control.
[0146] A Two-Stage Two-Sludge SBR3 was tested: one stage each for nitrification (N Stage) and denitrification (DN Stage), with DN Sludge on the mobile carriers that remain settled at the bottom of the tank when no external mixing is provided in the DN Stage (main role: denitrification) and the N Sludge consisting of the biofilm on the suspended carriers in N Stage (main role: nitrification). Activated sludge was also present, but not associated with any particular stage.
[0147] Configuration and Operation for Initial Phase of Testing
[0148] The initial configuration and operation of the SBR3 for nitrogen removal is shown in FIG. 3 and Table 1, respectively.
TABLE 1 Initial SBR3 Pilot Plant Configuration for Nitrogen Removal Carrier Main Function Configuration & Operation Volume % Denitrification BS Stage 50 L unaerated, variable vol. None DN Stage 150 L anoxic, variable vol. 50% Nitrification N1 Stage 200 L SBR cycle 50% N2 Stage 400 L SBR cycle 33% N/A Total Reactor Volume 800 L N/A Total HRT 10 Hrs Mixed Liquor Recycle ratio 20% N2 to BS & 80% N2 to DN (Total 160 L/Hr) SBR cycle: FILL Volume 320 L/cycle FILL Rate 160 L/Hr Cycle Time 4 Hrs FILL-AERATE 2 Hrs SETTLE/NON-AERATE 1 Hr DECANT/NON-AERATE 1 Hr
[0149] The two pilot-scale SBR systems were set up and operated in parallel at two different municipal sewage treatment works in Hong Kong (Site #1 and Site #2).
[0150] The sewage of Site #1 contained a large fraction of industrial wastewaters while the sewage of Site #2 was high in salinity resulting from seawater used for toilet flushing. Both sewages were known to require long operating sludge ages to achieve nitrification.
[0151] The carriers and the pilot SBRs were seeded with activated sludge from full-scale STWs. On-line raw sewage was collected after the grit removal chamber of the respective STW and flowed through a strainer and into a holding tank to allow continuous collection of raw sewage. Any surplus sewage collected was directed back to the grit chamber. The SBRs were fed following the average daily diurnal flow pattern mimicking the actual flow to the respective full-scale STWs.
[0152] The pilot plants were operated through experimental phases as shown in Table 2. For the Phase I testing, the initial conditions detailed in Table 1 and FIG. 3 were employed at both sites in order to fully stabilize the plants. Then, at both sites, the operating sludge age was reduced to observe the nitrogen removal capability (Phase II).
[0153] At Site #1, Phase II testing was continued with changes in key operational parameters, and with one change in the amount of carriers employed, to observe the nitrogen removal capability. Continuous or alternating reaction conditions (aeration, intermittent or continuous sewage feed, and constant or variable volume operation) were tested.
[0154] At Site #2, not all Phase II testing was continued. Instead, the configuration and operation were changed to incorporate phosphorus removal for Phase III testing (as illustrated in Case 3 in the following section).
[0155] Operation and Configuration Changes for Trial Testing
[0156] The changes are listed in Table 2 for the testing at Site #1 and Site #2.
TABLE 2 Operation and Configuration Changes for Case 2 Demonstration Sludge Phase SBR Modifications - Nitrogen Removal Age Days Date Site #1 I Conventional operation (i.e. typical operating sludge age) 15 45 11/6/02 to 26/8/02 II(a) Reduce sludge age to less than critical sludge age of 5 20 26/7/02 to nitrifiers 15/8/02 II(b) DN: Add intermittent aeration (i.e. alternating 5 15 15/8/02 to anoxic/aerobic). Conventional SBR not changed 30/8/02 II (c) All tanks: Change to continuous feed 5 15 30/8/02 to DN: no aeration 14/9/02 II(d) BS & DN: Change to constant volume operation. 5 15 14/9/02 to Decant volume increased from 40% to 53%. 29/9/02 All tanks: intermittent feed II(e) N1: Change to constant volume & constant aeration 5 15 29/9/02 to Transfer carriers from N2 (33%-25%) to N1 (50%-66%). 14/10/02 Increase number of cycles per day from 6 to 9 Total 125 Site #2 I Conventional operation (i.e. typical operating sludge age) 15 30 21/11/02 to 21/12/02 II Reduce sludge age to less than critical sludge age of 5 15 21/12/02 to nitrifiers 5/1/03 Total 45
[0157] Results
[0158] The 24-hour average influent and effluent characteristics for a 5-day period during each phase of the stabilized SBR3 at Sites#1&2 are shown in FIGS. 8C-8H. The average influent characteristics of STW Site#1 are shown in FIG. 8C. The average effluent characteristics of SBR3 at Site#1 are shown in FIG. 8D. The average effluent characteristics of conventional SBR at Site#1 are shown in FIG. 8E. The average influent characteristics of STW Site#2 are shown in FIG. 8F. The average effluent characteristics of SBR3 at Site#2 are shown in FIG. 8G. The average effluent characteristics of conventional SBR at Site#2 are shown in FIG. 8H.
[0159] The daily effluent nitrogen concentration of the SBR3 operated at the STW Site#1 for 65 days is shown in FIG. 8I. The daily effluent nitrogen concentration of the SBR3 operated at STW Site#2 for 53 days is shown in FIG. 8J. The daily effluent ammonia and phosphate concentrations of the SBR3 operated at STW Site#2 for a 45 days are shown in FIG. 8K. For any process operation disruption of the SBRs, only effluent samples from properly operated cycles were tested and documented.
[0160] SBR3 and Conventional SBR—Nitrification-Denitrification Performance
[0161] During Phase I of each STW Site, both SBRs at Site#2 and the SBR3 at Site#1 after biomass stabilization were able to consistently achieve complete nitrification (effluent NH 4 —N<1-2 mg/L and ˜80% removal of nitrogen (effluent NO 3 —N<10 mg/L). The conventional SBR at Site#1 had slightly higher effluent ammonia of ˜4 mg/L. at both sites. The effluent soluble COD (SCOD) concentrations of STW Site#1 were always higher probably resulting from the large industrial wastewater contributions. This also led to higher effluent NH 4 —N and NO 3 —N concentrations than those of Site#2, despite having similar influent TCOD: TKN ratios of ˜10 to 11. In addition, the overall higher total biomass contents with the biofilm carriers allowed the SBR3 of both Sites having noticeable better nitrification-denitrification performance. It also appeared that the conventional SBR of Site#1 was operated at near their maximum capacity because the effluent NH 4 —N concentration was frequently higher than the target 2 mg/L level.
[0162] The nitrifiers maximum specific growth rates is the key characteristics of sewage determining the hydraulic and organic capacity requirements of the conventional SBR process, i.e. the size of the SBR basin. These values of Sites # 1 & 2 were determined to be 0.2 and 0.3/Day, respectively, at the end of this Phase. The significantly lower nitrifiers maximum specific growth rate level of Site#1 further indicated the impact of the industrial wastewater discharges. However, the apparent maximum specific growth rate of nitrifiers of the SBR3 were significantly (>30%) higher than that of the conventional SBRs.
[0163] Low buffering capacity of the sewage was also noticed. At the end of FILL-AERATE sequence, aerobic reactor pH levels were frequently lower than 7, while values as low as 6.5 was also recorded on a number of occasions. Low operating pH of 6.5-7 would lead in up to 50% reduction of the maximum nitrification rate as compared to that at the most optimal pH range of 7.8-8.2. Highly variable chloride concentrations ranging from 3,500 to 7,000 mg/L were also known to adversely affect nitrification rate. However, these adverse effects were largely recovered with incorporation of biofilm in the SBR3 activated sludge technology.
[0164] During Phase II(a) and Phase II of the respective Sites, reducing the operating sludge age to less than 10% of the critical sludge age (˜5 days) demonstrated clearly the better advantages of the SBR3s of site #1 than that of the conventional SBRs of site #2. The conventional SBR effluent NH 4 —N levels increased sharply at the end of this Phase (FIGS. 8I & 8J), as compared to those levels of the SBR3s showed a slight increase (˜1-2 mg NH 4 —N/L) but with more fluctuations. The high MLSS concentrations of ˜3,500 mg/L of the SBRs, the typical maximum SBR operating level, were also reduced dramatically to ˜1,500 to 1,700 mg/L. This greatly assisted the SETTLE and DECANT sequences efficiency. With the growth pressure created by the Bio-selector, the sludge settleability improved (SVI values were mostly less than 125 mL/g). Higher effluent TSS concentration, particularly during Phase II, was observed for Site#2 with significantly higher total dissolved solids concentration.
[0165] For Site#1 only, a number of different operating modes and configurations, as detailed in Table 2, were also practiced for nitrification-denitrification performance evaluation. These included intermittent vs. continuous feed, constant-vs. variable-volume operation of the Anoxic stage(s) and continuous-Anoxic vs. Alternating Anoxic/Aerobic configurations. These were not repeated in Site#2. However, different operating modes and configurations for nitrogen and phosphorus removal were tested. This was because the sewage of Site#1 did not show any favorable characteristics such as high level of readily biodegradable COD and good denitrification (effluent NO 3 —N<5 mg/L).
[0166] As indicated in FIGS. 8D and 8E, there were no significant changes in nitrogen removal performance for 15 days of each of the different operating modes and configurations tested.
[0167] Case 3 Three-Stage and Three-Sludge Anaerobic-Anoxic-Aerobic Process for Organics-Suspended Solids-Phosphorus and Nitrogen Removal
[0168] One of the possible three-stage three-sludge SBR3 system configurations is illustrated in FIG. 4. This configuration consists of a P Stage, which is sub-divided into two sub-tanks 444 and 446 . The P Sludge consists of the suspended mixed liquor biomass, which contains enhanced biological phosphorus (bio-P) removal microorganisms. The bio-P microorganisms are developed due to their free movement through the bioreactor and mixed liquor recycle and thus, exposure to cyclic anaerobic-aerobic conditions made possible by the incorporation of the P Stage anaerobic condition. The DN Stage and DN Sludge, and N Stage and N Sludge are similar to Case 2. A variable-volume decanting device is provided in the N Stage, which is operated in SBR mode, as illustrated in FIGS. 9A and 9B. The cycle starts from step 9 A 1 , going through steps 9 A 2 , 9 B 1 , and 9 B 2 , and goes back to step 9 A 1 . In this process, the three tanks are used for:
[0169] (1) The first stage P: P 1 (unaerated, as performed in the first tank 444 ) and P 2 (unaerated and anerobic, as performed in the second tank 446 )
[0170] (2) The second stage DN (as performed in the third tank 448 )
[0171] (3) The third stage N (as performed in the fourth tank 450 )
[0172] For the ease description of the bio-chemical processes, the following description contains reference only to the biochemical stage without further reference to the particular tanks as shown in FIG. 4, 9A or 9 B. It is understood that these processes are performed in the respective tanks.
[0173] The P and DN stages are also variable-volume in this example, but either may also be operated in constant-volume mode.
[0174] The P Stage receives influent wastewater which may be split between the sub-tanks 444 and 446 and the sub-tank 444 may also receive return mixed liquor from the end of the DN Stage and/or the end of the N Stage. This first P Stage sub-tank 444 is un-aerated and conditions are aerobic, anoxic or anaerobic, depending on the level of the oxygen species present mainly from the N Stage recycle. Anoxic conditions are due to the nitrate in the recycled nitrified mixed liquor. The amount of mixed liquor recycle to the P Stage will be controlled during the aeration sequence so that the dissolved oxygen and nitrate oxygen recycle will not adversely affect the bio-P removal performance. Settled sludge from the N Stage will be recycled to the P Stage to enhance bio-P removal, if required. If aeration is used in the P Stage, aerobic conditions would be promoted. If enhancement of P removal is desired, the recycle of mixed liquor from the end of the DN Stage may be utilized since this would promote anaerobic conditions in the P Stage. The second P Stage sub-tank 446 is unaerated and conditions are mainly anaerobic.
[0175] The P Stage is dominated by fast growing bacteria, which are capable of degrading readily biodegradable organics (RBCOD), and also the bio-P microorganisms which release P in anaerobic conditions (and uptake P in anoxic or aerobic conditions). Whereas most of the P uptake occurs in the DN and N stages, it also can occur in the P Stage. In the P Stage, mixing may or may not be provided.
[0176] During settle and decant sequences of the N Stage, the settled biomass from the P-rich MLSS can be removed (e.g. wasted) thereby removing the P.
[0177] The DN and N Stages will be operated similar to those of Case 2, except that some of the RBCOD from the influent has already been absorbed for bio-P removal.
[0178] The duration of the three-stage three-sludge SBR3 system operating cycle can be less than two hours to up to twenty-four hours. The total HRT can be shorter than six hours. The P and/or DN stages may employ constant volume operation while the N Stage will be operated with variable volume mode. A bio-selector as part of the P Stage will optionally be incorporated to control biological foaming and bulking, particularly if the MLSS is high. Sludge wasting is either separately for the DN or N Stages or together from the N Stage during the settling sequence.
[0179] Case 3 Experimental Data
[0180] Two fully automatic PLC controlled SBR pilot-scale reactors were built including an on-line wastewater sampling, monitoring and control system. The SBR3 included biofilm carriers with configuration as shown in FIG. 5 and the “conventional SBR” was identical to the SBR3 except that it had no biofilm carriers and was used as a control.
[0181] A Three-Stage Three-Sludge SBR3 was tested: same as the Two-Stage Two-Sludge SBR3 except that a third stage (P Stage) was added for phosphorus removal, with the third P Sludge consisting of the activated sludge, which is suspended and flowing through all the tanks (main role: phosphorus removal by cyclic anaerobic phosphorus release and aerobic or anoxic uptake).
[0182] Configuration and Operation for Initial Phase of Testing
[0183] The initial configuration and operation of the SBR3 for nitrogen and phosphorus removal is shown in FIG. 5 and Table 3, respectively.
TABLE 3 Initial SBR3 Pilot Plant Configuration for Nitrogen & Phosphorus Removal Carrier Main Function Configuration & Operation Volume % Phosphorus P1 Stage 25 L unaerated, variable vol. None Release P2 Stage 25 L anaerobic, variable vol. None Denitrification DN1 Stage 75 L anoxic, variable vol. 50% DN2 Stage 75 L anoxic, variable vol. 50% Nitrification N1 Stage 200 L SBR cycle 50% N2 Stage 400 L SBR cycle 33% N/A Total Reactor Volume 800 L N/A Total HRT 10 Hrs Mixed liquor Recycle ratio 20% N2 to P1 & 80% N2 to DN1 (160 L/Hr) SBR cycle: FILL Volume 320 L/cycle FILL Rate 160 L/Hr Cycle Time 4 Hrs FILL-AERATE 2 Hrs SETTLE/NON-AERATE 1 Hr DECANT/NON-AERATE 1 Hr
[0184] The two pilot-scale SBR systems were set up and operated in parallel at a municipal sewage treatment works in Hong Kong (Site #2) with the initial Phase III conditions shown in Table 3. Phase III testing was continued with changes in key operational parameters, and with one change in the location of the mixed liquor return, to observe the combined nitrogen and phosphorus removal capability.
[0185] Operation and Configuration Changes for Trial Testing
[0186] The changes are listed in Table 4 for the testing at Site #2.
TABLE 4 Operation and Configuration Changes for Case 3 Demonstration Site #2 SBR Modifications - Nitrogen & Phosphorus Removal Sludge Age Days Date Maintain sludge age less than critical sludge age of 5 20 5/1/03 to nitrifiers (same as in Phase II). 25/1/03 Re-route the mixed liquor recycle of the P1 Stage such 5 10 25/1/03 to that it is from DN2 Stage rather than N2 Stage. 4/2/03 Conventional SBR not changed DN1 & DN2: Add intermittent aeration (i.e. 5 5 4/2/03 to alternating anoxic/aerobic). Change the P1 Stage 8/2/03 mixed liquor recycle back to (a), i.e. N2 Stage. Conventional SBR not changed P1 & P2 Stage: Change to constant volume operation. 5 5 8/2/2003 to Decant volume increased from 40% to 43%. 16/2/03 DN1 & DN2: no aeration All tanks: Change to continuous feed 5 8 16/2/03 to P1 & P2 Stage: variable volume operation, as in (a) 24/2/03 Total 48
[0187] Results
[0188] The 24-hour average influent and effluent characteristics for a 5-day period during Phase III at Site#2 are shown in FIGS. 8F, 8G, and 8 H. The average influent characteristics of STW at site#2 are shown in FIG. 8F. The average effluent characteristics of SBR3 are shown in FIG. 8G. The average effluent characteristics of conventional SBR are shown in FIG. 8H.
[0189] The daily effluent nitrogen concentration of the SBR3 operated at the STW for 25 days is shown in FIG. 8J. The daily effluent ammonia and phosphate concentrations of the SBR3 operated at STW for 48 days are shown in FIG. 8K. For any process operation disruption of the SBRs, only effluent samples from properly operated cycles were tested and documented.
[0190] SBR3 and Conventional SBR—Nitrification-Denitrification and Phosphorus Removal Performance
[0191] At the end of Phase II at Site#2, it was observed that the effluent phosphate levels were gradually decreasing when the conventional SBR was being operated with highly restricted nitrification. It was then decided to test the SBR3 nitrogen together with phosphorus removal using different operating modes and configurations (Table 4).
[0192] The configuration modifications of SBR3 for phosphorus removal included incorporation of an anaerobic stage (an additional Stage) and an extra mixed liquor recycle from the end of the anoxic stage to the first anaerobic stage. Phosphorus removal was quickly developed within two operating sludge ages (˜2*5 days). However, the effluent phosphate levels of less than 1 mg/L could not be achieved unless there was addition of external readily biodegradable COD of up to 50 mg/L using acetate (FIG. 8K). This clearly showed that the content of readily biodegradable COD in the sewage was not sufficient, as expected from high SO 42 -content from the seawater contribution.
[0193] Changing the mixed liquor recycle to the P 1 sub-tank from the previous location at the end of the aerobic stage to the end of the anoxic stage did not reveal any improvement. Other operating modes with intermittent vs. continuous feed, constant- vs. variable-volume operation of the P Stage and intermittent aeration of the anoxic stage also did not demonstrate any obvious advantage or disadvantage.
[0194] As mentioned above, means for stage generation may be any devices or built-in or add-on design of the system that allows the desired conditions to be attained for the appropriate biochemical parameters or bioreactor functions. Besides devices such as mixer, aerator, heater, cooler, trickier, or pump, other conditions achievable by design include, for example, the relative positioning of the two or more tanks to make use of gravity to allow fluid to flow from one tank to the next via one or more flow channels, etc. The tanks can also be separated vertically. In another embodiment, the first and second tanks are disposed some vertical distance from each other, and the means for generation of the stages consists of channels for interconnecting fluid flow between the first and second tanks. Wastewater can also be any type, including high levels of organic compounds and does not exclude 100% organics. Furthermore, first or second sludge refers to biomass with emphasis on its uniqueness but is not meant to exclude other biological activities besides the one specified in the text. The carriers on which the sludges grow can be mobile, remain settled at the bottom of the tank when no external mixing is provided (i.e. intermittently suspended), or can be completely fixed depending on the requirement of the system. The flow channels may be lined, for example, with gravel arranged in such a way as to generate splashes or droplets to create a large surface area for the absorption of oxygen into the fluid before influence into the second tank. The second tank may then be used for aerobic removal of nitrogen and/or phosphorus according to the user's requirements. Other means for stage generation, such as heater or trickier, may also be used in combination therewith for further control of stage conditions. Moreover, the arrangement of stages in the text does not represent sequential order, the chronological order is used to distinguish between one stage to another and for the ease of understanding. The means of influence and effluence is not restricted to the first tank and may be in the first, second or third tank depending on the requirements.
[0195] Case 4 Three-Stage and Three-Sludge Anaerobic-Anaerobic-Anaerobic Process for Organics-Suspended Solids
[0196] One of the possible three-stage three-sludge SBR3 system configurations is illustrated in FIG. 6. The cycle sequence of the SBR3 process of case 4 is illustrated in FIGS. 10A and 10B. The cycle starts from step 10 A 1 , going through steps 10 A 2 , 10 B 1 , and 10 B 2 , and goes back to step 10 A 1 . In this process, the enclosed three tanks are used for:
[0197] (1) The first stage HP (performed in the first tank 601 );
[0198] (2) The second stage AC (performed in the second tank 602 );
[0199] (3) The third stage MP (performed in the third tank 603 ).
[0200] For the ease of description of the bio-chemical processes, the following description contains reference only to the biochemical stage without further reference to the particular tanks as shown in FIG. 6, 10A or 10 B. It is understood that these processes are performed in the respective tanks.
[0201] This configuration consists of a HP Stage with HP Sludge consisting of the biofilm on the mobile carriers, an AC Stage with AC Sludge consisting of the biofilm on the fixed or mobile carriers and a MP stage with MP Sludge consisting of the biofilm on the fixed or mobile carriers. A variable-volume emptying device is provided in the MP Stage, which is operated in SBR mode, as illustrated in FIG. 10. Note that in this case, the HP and AC Stages have constant volume but either may also be designed and operated in variable-volume mode.
[0202] The HP Stage receives influent wastewater and may also receive return mixed liquor (ML) from the AC and/or MP Stages for better control of reaction conditions, either continuously or intermittently. The HP Stage is operated, particularly for industrial wastewaters containing high solids concentration, for hydrolysis of particulate organic matter by extracellular enzymes to soluble organic molecules such as sugar, fatty acids and amino acids. The HP Sludge is dominated by slow-growing bacteria, which are capable of hydrolysis of particulate organic matter to more readily biodegradable organics. Together with high operating temperature in the thermophilic range (50 to 60° C.), the higher concentration of HP sludge can speed up the hydrolysis process from 10-20 days to 2-5 days. The carriers together with the particulate organics are, mobile carriers that remain near the bottom of the tank because they are slightly heavier than water, of up to 70% of the tank volume are provided for biomass attachment. The mobile carriers may only be temporarily suspended by intermittent mixing to allow the soluble organics to be release to the bulk liquor but at the same time minimize contact with the soluble organics.
[0203] Mixed liquor in the HP Stage is in intermittent communication, i.e. during the settle and decant sequences, with mixed liquor in the AC Stage by any means of flow interconnection, e.g. overflow, channels, pumping, etc. A mesh is placed at each opening to prevent any biofilm carriers from going from one stage to the other. The AC Stage contains suspended carriers of up to 70% of the volume. The carriers may be intermittently or continuously mixed, depending on conditions in the tank. This stage, which may also receive return mixed liquor from the MP Stage for better control of reaction conditions, either continuously or intermittently, acts as an acid-forming/acidogenic step to convert bytyric and propionic acids to acetic acid. Thus, the biofilm AC Sludge will have a unique composition. Carriers of the AC Stage may also minimize the solids-liquid separation requirement such that a settle reaction sequence is not necessary and so allows the mixed liquor in the AC Stage to be in continuous communication with mixed liquor in the MP Stage by any means of flow interconnection, e.g. overflow, underflow, channels, pumping, etc. A mesh is placed at each opening to prevent any biofilm carriers from going from one stage to the other.
[0204] Similarly, the MP Stage contains suspended carriers of up to 70% of the tank volume depending on the decant percentage. The carriers may be intermittently or continuously mixed, depending on conditions in the tank. This stage mainly acts as a methane producing step. Mixing is provided by both mechanical mixing and biogas production in the mixed liquor. The biogas is collected for further handling. The MP Stage may also perform as a secondary clarifier for solids-liquid separation (SBR operation mode). When the mechanical mixing is OFF during the settle sequence, the carriers and activated sludge settle to the bottom. Contact between the acetic acid in the bulk liquid with the MP sludge is minimized. The resultant reduced biogas production allows better settling of carriers and suspended sludge before emptying of the effluent.
[0205] The duration of the SBR3 operating cycle can be less than two hours to up to twenty-four hours. The total HRT can be shorter than six hours. The HP and AC Stages can employ either constant or variable volume operation while the MP Stage will be operated with variable volume mode. Sludge wasting is either separately for each stage or together from the NP Stage during the settling sequence.
[0206] While the present invention has been described in detail using the case studies and embodiments shown above, they are for illustration only, and are not meant to limit the scope of the invention, which is defined by the claims appended herein. It is clear from the aforementioned examples that enormous numbers of variations and combinations are possible based on the teaching provided herein. For example, the carriers in the embodiments shown are mobile carriers. However, it is clear that the carriers may also be fixed carriers, but with other means for stage generation being used to create a suitable environment for growth of the desired sludge for the desired bioreaction stage. The type of carriers and amount used are variable. Mixing is provided by various means, either continuously or intermittently, to create the desired conditions for growth of a desired sludge to perform the desired bioreaction stage. For anaerobic conditions, the mixers, even if they are provided in the tank, may be completely inactivated such that the carriers are completely settled at the bottom of the tank to minimize oxygen that can reach thereto. While one tank usually involves only one stage in the illustrations, it is noted that there may be more than one stage within a tank due to differences of conditions. For the stages where variable volume mode is employed, constant volume mode can also be employed, and vice versa. Although the description and the claims recite biomass that are grown on carriers for the various bioreaction stages, this is not intended to preclude the presence of activated sludge that is found in suspension. It is clear that such activated sludge also contributes to the bioreaction of the various stages as described in the aforementioned examples. Furthermore, while the range of operating temperatures is indicated in some of the illustrations, it is clear that the temperature ranges are highly dependant on other operation conditions and may be determined by one of ordinary skill in the art without undue experimentation based on the teachings provided herein.
[0207] Several types of means for stage generation such as the mixer, aerator, gas generator, heater and cooler pump are mentioned in above illustrations and in the claims, but it is clear that such examples are for illustration only and that other such means would also fall within the scope of the claims, including the use of architectural arrangements to take advantage of physical forces such as gravity. | A new biofilm-activated sludge Sequencing Batch Reactor (SBR) treatment process for sewage or wastewater has successfully been developed as the third generation SBR (SBR3). This new SBR3 process utilizes a multi-stage and multi-sludge SBR configuration receiving either continuous or intermittent inflow of wastewater. Each stage has individually controlled continuous or alternating anaerobic/anoxic/aerobic operation, with or without mixing and recycling from the other stage(s). The configuration and operation is dependent upon the treatment objectives and effluent discharge requirements. In the preferred embodiment, carriers are used to facilitate control of operating conditions. | 8 |
This application is national phase of PCT/US2010/026810 filed Mar. 10, 2010, and claims the benefit of priority of Provisional U.S. Patent Application Ser. No. 61/167,616, filed Apr. 8, 2009, entitled “SYSTEM AND METHOD FOR FABRICATING AN ULTRASONIC LIQUID SENSOR”.
CROSS-REFERENCE TO RELATED APPLICATION
This application claims the benefit of priority of Provisional U.S. Patent Application Ser. No. 61/167,616, filed Apr. 8, 2009, entitled “SYSTEM AND METHOD FOR FABRICATING AN ULTRASONIC LIQUID SENSOR”.
BACKGROUND OF THE INVENTION
The present invention is directed to a sensing device. More particularly, the present invention pertains to a sensing device used to detect the presence or absence of liquid within a tube.
Fluid or liquid within a tube or conduit may be detected using ultrasonic waves. Typically, a transmitting transducer is positioned on one side of a tube and a receiving transducer is positioned on the opposing side of the tube. The transmitting transducer emits an ultrasonic signal, which is propagated through the tube wall and into the tube itself. If the tube is empty, no signal is received by receiving transducer. If there is liquid present in the tube, however, the receiving transducer receives a signal and conveys the signal to, for example, a control circuit.
Typically, the ultrasonic energy is generated and received by a pre-made joint sensor system consisting of a transmitting transducer and receiving transducer pre-fastened to a hollow, open-ended sleeve. In order to use the joint sensor system with a desired tube, a section of the tube is removed and the joint sensor system is joined to the tube at the area where the portion of tube has been removed. The tube is connected to the sleeve such that liquid passes through the sleeve, and the joint is then sealed at each end of the sleeve to the tube. The joint sensor system then becomes an integral part of the tube. While effective, such joints and seals are prone to leakage. In addition, placing the sensor integrally within the line of the tube is not only time-consuming, but also expensive.
In another embodiment, transducers are applied directly to the tube sidewalls with fastening agents such as screws or chemical means, such as adhesive. Unfortunately, these fastening agents do not always maintain a secure connection and may absorb and/or distort the ultrasonic waves. In addition, in this configuration, the bottom electrode of the transducer may not be in electrical communication with the control circuit effectively, and thus, the signal becomes distorted and/or attenuated.
Accordingly, there is a need for an ultrasonic liquid sensing device that maintains contact with the tube and does not distort or otherwise interfere with the transmission and reception of ultrasonic waves. Such a sensor is easy to mount and can be used and re-used with a variety of different sized and shaped tubes. Most desirably, no cutting of the tube is necessary and the tube maintains its structural integrity.
BRIEF SUMMARY OF THE INVENTION
An ultrasonic liquid sensor for detecting liquid in a tube having sidewalls includes a first intermediate mounting plate, a second intermediate mounting plate, a first transducer element, and a second transducer element. The first and second intermediate mounting plates are held in constant physical communication with a first and second sidewall, respectively, of the tube and are configured to allow an ultrasonic signal to pass therethrough. The plate can be fabricated from metal or non-metal materials. The non-metal plate can have conductive material included therein to provide an electrical connection path for the transducer circuitry.
The intermediate mounting plates have first and second sides. The second sides of the intermediate mounting plates are held in close physical communication with the sidewalls of the tube, while the transducers are mounted to the opposing (first) sides of each of the intermediate mounting plates such that, in a use-position, the intermediate mounting plates are positioned between the tube sidewalls and the transducers.
The first transducer element, mounted to the first intermediate mounting plate, is configured to transmit an ultrasonic signal through the first intermediate mounting plate and the first sidewall of the tube. The second transducer element, mounted to the second intermediate mounting plate, is configured to receive the ultrasonic signal passing through the second sidewall of the tube and through the second intermediate mounting plate, in order to determine the presence or absence of liquid in the tube. The sensor can be enclosed in a self-contained unit.
In an embodiment, the intermediate mounting plates have sufficient rigidity and strength to maintain continual and consistent direct, physical contact with the sidewalls of the tube while interfacing directly with a secondary electrical circuit. In another embodiment, a support assembly and/or a housing base assists in maintaining the intermediate mounting plates in direct, physical contact with the sidewalls of the tube. The support assembly and housing bases can both be formed of metal material or non-metal material and can serve to interface with the sensor and a secondary circuit. In an embodiment, the support assembly and/or housing bases provide rigid support to the intermediate mounting plates without the use of screws or adhesive while maintaining the shape and integrity of the tube and without attenuating or interfering with the sensor signal.
These and other features and advantages of the present invention will be apparent from the following detailed description, in conjunction with the appended claims.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
The benefits and advantages of the present invention will become more readily apparent to those of ordinary skill in the relevant art after reviewing the following detailed description and accompanying drawings, wherein:
FIG. 1 is a perspective view of a portion of an ultrasonic liquid sensor;
FIG. 2 is a top view of the ultrasonic liquid sensor in accordance with the principles of the present invention;
FIG. 3 is a perspective photograph of a plurality of the present sensors mounted to a printed circuit board;
FIG. 4 is a perspective view of an intermediate mounting plate and transducer;
FIG. 5 is a perspective view of a shared contact;
FIG. 6 is a perspective view of an array of an embodiment of the present sensors;
FIG. 7 is a perspective view of the array of FIG. 6 ;
FIG. 7A is a top view of the array of FIG. 7 with a support assembly and housing bases;
FIGS. 8 and 9 are perspective views of another embodiment of the present sensor;
FIG. 10 is a perspective view of an array of the sensor embodiment of FIGS. 8 and 9 ; and
FIG. 11 is a top view of the array of FIG. 10 .
DETAILED DESCRIPTION OF THE INVENTION
While the present invention is susceptible of embodiment in various forms, there is shown in the drawings and will hereinafter be described a presently preferred embodiment with the understanding that the present disclosure is to be considered an exemplification of the invention and is not intended to limit the invention to the specific embodiment illustrated.
It should be further understood that the title of this section of this specification, namely, “Detailed Description Of The Invention”, relates to a requirement of the United States Patent Office, and does not imply, nor should be inferred to limit the subject matter disclosed herein.
In the present ultrasonic liquid sensor, an ultrasonic signal is propagated between two transducers, through the material of intermediate mounting plates, and through a tube, in order to determine the presence or absence of liquid in the tube. In the present disclosure, “liquid” refers to any fluid medium capable of propagating an ultrasonic signal therethrough and includes any water-based or oil-based solution or mixture, gels and the like. In addition, a “tube” refers to any hollow conduit through which liquid may be passed and have any shaped cross-section, including but not limited to circular, rectangular, squared, oval, and the like.
Referring now to the figures and in particular FIGS. 1 and 2 , there is shown an exemplary embodiment of an ultrasonic liquid sensor 100 (“sensor”) in accordance with the principles of the present invention. The sensor 100 includes a pair of intermediate mounting structures, hereafter referred to as first and second intermediate mounting plates 110 , 111 respectively, as well as a transmitting transducer 116 and a receiving transducer 117 .
The first and second intermediate mounting plates 110 , 111 can be relatively flat plates, discs, or other shaped elements. The first and second intermediate mounting plates 110 , 111 may be fabricated from conductive or non-conductive materials and can include, but are not limited to, aluminum, steel, stainless steel, common die casting materials such as zinc, brass, plastics such as polyphenylene sulfide (PPS), fiberglass materials such as printed circuit board material (FR4), and mechanically rigid thermoset. It will be appreciated by those skilled in the art that this list is not exhaustive and includes any type of material which allows ultrasonic waves to pass through without distorting or attenuating the ultrasonic signal unduly.
The first intermediate mounting plate 110 has a first side 112 A and a second side 112 B. Similarly, the second intermediate mounting plate 111 also has a first side 113 A and a second side 113 B. Each intermediate mounting plate 110 , 111 is rigid, and in a use-configuration is positioned with second sides 112 B and 113 B placed in physical communication with the outer sidewalls of the tube T.
The transmitting transducer 116 is mounted to the first intermediate mounting plate 110 . The transmitting transducer 116 has a top side 118 (with a top electrode 119 ) and a bottom side 120 (with a bottom electrode 121 ). The bottom side 120 of the transmitting transducer 116 is mounted to the first side 112 A of the intermediate mounting plate 110 . The bottom side 120 may be bonded to a conductive pad 122 on the intermediate mounting plate 110 or may be bonded to the intermediate mounting plate 110 directly if the intermediate mounting plate 110 is formed of a conductive material.
Similarly, the receiving transducer 117 is mounted to the second intermediate mounting plate 111 . The receiving transducer 117 has a top side 128 (including a top electrode 129 ) and a bottom side 130 . The bottom side 130 (including a bottom electrode 131 ) of the receiving transducer 117 is mounted to the first side 113 A of the intermediate mounting plate 111 . The bottom side 120 of the receiving transducer 117 may be bonded to a conductive pad 123 on the intermediate mounting plate 111 or may be bonded to the intermediate mounting plate 111 directly if the intermediate mounting plate 111 is formed of a conductive material.
In an embodiment shown in FIGS. 2 and 3 , sensor 100 includes a support assembly 140 for the intermediate mounting plates 110 , 111 . The support assembly 140 may be manufactured from plastics or metals, from conductive, non-conductive, or a combination of conductive and non-conductive material. Such materials, as discussed above, can include, but are not limited to, aluminum, steel, stainless steel, common die casting materials such as zinc, brass, plastics such as polyphenylene sulfide (PPS), common injection molding materials, fiberglass materials such as printed circuit board material (FR4), and mechanically rigid thermoset. The support assembly 140 may include any circuitry necessary to interface with a secondary circuit 150 and the sensor 100 .
It will be appreciated by those skilled in the art that a support assembly may not be required; the intermediate mounting plates may be formed with sufficient rigidity and strength to maintain physical contact with the sidewalls of the tube without additional support. It will also be appreciate by those skilled in the art that in an embodiment having no support assembly as described, an interface between the sensor and a control circuit or other secondary circuit may still be required and is anticipated and contemplated by the present disclosure.
In another exemplary embodiment shown in FIGS. 4-7 , a sensor 400 includes an intermediate mounting plate 410 , a transducer 416 , and a shared contact 460 . The transducer 416 can be configured as a transmitting transducer or as a receiving transducer. In a use-position, as shown in FIG. 6 , the shared contact 460 is positioned between two sensor assemblies 400 ( 400 A and 400 B), contacting the transducers 416 of each of the two sensor assemblies. Tubes T 1 , T 2 , and T 3 , may be positioned between the intermediate mounting plates with additional support for the intermediate mounting plates provided by the support assembly 440 and/or the housing base 470 , as shown in FIGS. 6 , 7 , and 7 A.
In yet another exemplary embodiment shown in FIGS. 8-11 , sensor 800 includes a pair of intermediate mounting plates 810 , 811 with a transducer 816 sandwiched between intermediate mounting plates 810 , 811 . In a use-configuration, as shown in FIG. 10 , sensor 800 A is paired with other sensors 800 B, 800 C, and 800 D. In the example shown in FIG. 10 , three tubes T 1 , T 2 , and T 3 are positioned between two adjacent sensors 800 , such that the intermediate mounting plates 811 of each sensor 800 is in physical contact with the sidewall of one tube and the intermediate mounting plate 810 is in physical contact with the sidewall of an adjacent tube. In the embodiment shown in FIG. 10 , a housing base 870 and/or support assembly 840 is also present.
In the embodiments discussed above, the sensor operates in a manner such that an ultrasonic signal is transmitted from the transmitting transducer, propagates through the first intermediate mounting plate, through the tube first sidewall, through any liquid present, through the opposite sidewall (second sidewall) of the tube, and through the second intermediate mounting plate of the sensor until it is finally received by the receiving transducer. The signal is then transformed by the transducer and relayed to a control circuit or the like to indicate the presence or absence of liquid within the tube. It will be appreciated by those skilled in the art that the transducers themselves are not in physical contact with the sidewalls of the tubes; it is the intermediate mounting plates which maintain physical contact with the sidewalls.
For example, in FIGS. 1-3 , the sensor 100 , the transmitting transducer 116 , mounted to the first intermediate mounting plate 110 , emits an ultrasonic signal. The material of the first intermediate mounting plate 110 is capable of allowing the ultrasonic signal to pass through without modifying, attenuating, or distorting the ultrasound signal. The intermediate mounting plate 110 is in physical communication with the sidewall of the tube T such that the ultrasound signal then passes into the tube T. If there is no liquid present in the tube T, the ultrasound signal will stop or not continue to propagate.
If, however, there is liquid present, the ultrasound signal will propagate through the liquid and penetrate the opposing sidewall of the tube T. As with the first intermediate mounting plate 110 , the second intermediate mounting plate 111 is also made from a material which allows the ultrasound signal to pass through, again without modification, attenuation, or distortion. The ultrasound signal is received by the receiving transducer 117 . The receiving transducer 117 can then convert the ultrasound signal to an electrical signal and relay that signal to a secondary circuit 150 such as a control circuit. The electrical signal may be relayed through the circuitry enclosed in the support assembly interface, or directly from the transducer through another form of electrical interface.
In the embodiments shown in FIGS. 4-7 and 8 - 11 , the number of individual components needed when used with a plurality of tubes can be decreased. In the embodiments of FIGS. 4-7 and 8 - 11 , because the transducers serve as dual mode transducers (i.e. act as both transmitting and receiving transducers) fewer components are necessary in these embodiments.
For example, in FIGS. 4-7 , the sensors 400 A, 400 B, and 400 C operate in essentially the same manner as the embodiment shown in FIG. 3 and described above, with a slight modification. The pair of mounting plates 400 provide the same ultrasonic function as mounting plates 110 and 111 above, but with the use of the shared contact 460 , the plates 410 and shared contact 460 provide an electrical path for both the transmitting and receiving transducer pairs.
In another example shown in FIGS. 8-11 , the sensors 800 A, 800 B, 800 C, and 800 D operate the same way as the embodiment shown in FIG. 3 and described above, again with a slight modification. The pair of mounting plates 800 provide the same ultrasonic function as mounting plates 110 and 111 , but with the use of plates 810 and 811 an electrical path for both the transmitting and receiving transducer pairs is provided and when placed between a pair of liquid tubes, for example, T 1 and T 2 or T 2 and T 3 as shown in FIG. 10 , a single transducer and plate assembly 800 situated between the tubes can alternate between the function of a transmitter for one tube and a receiver for the other tube.
The advantages to the present ultrasonic liquid sensor will be appreciated by those skilled in the art. The sensor provides a cost-effective assembly and method for determining the presence or absence of liquid in a tube. The present sensor eliminates the need for the tube to be cut in order for the sensor to be inserted, thus maintaining the integrity of the tube. The present sensor is easy to install and maintain. In addition, the sensor can be re-used with different tubes and can be adjusted to fit any diameter tube.
All patents referred to herein, are incorporated herein by reference, whether or not specifically done so within the text of this disclosure. In the present disclosure, the words “a” or “an” are to be taken to include both the singular and the plural. Conversely, any reference to plural items shall, where appropriate, include the singular.
From the foregoing it will be observed that numerous modifications and variations can be effectuated without departing from the true spirit and scope of the novel concepts of the present invention. It is to be understood that no limitation with respect to the specific embodiments illustrated is intended or should be inferred. The disclosure is intended to cover by the appended claims all such modifications as fall within the scope of the claims. | An ultrasonic liquid sensor for detecting liquid in a tube having sidewalls includes a first intermediate mounting plate held in physical communication with a first sidewall of the tube, a second intermediate mounting plate held in physical communication with the second sidewall of the tube. The plates are configured to allow the ultrasonic signal to pass therethrough. The sensor also includes a first and a second transducer element. The first and second transducer elements are mounted to the intermediate mounting plates and are configured to receive the ultrasonic signal passing through the sidewalls of the tube as well as the intermediate mounting plates to determine the presence or absence of liquid in the tube. The sensor can be enclosed in a self-contained unit and a support assembly can be used and formed of metal material or non-metal material to interface with the sensor and a secondary circuit. | 6 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims the priority of German Application No. 100 53 139.3 filed Oct. 26, 2000, which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] This invention relates to a device in a fiber processing machine, such as a carding machine or a cleaner for setting the distance between cooperating clothings, such as the clothing of the main carding cylinder of a carding machine and the clothing of a flat bar of a traveling flats assembly.
[0003] The distance between the clothing of the main carding cylinder and the clothing of a member cooperating therewith is of substantial significance as far as machine technology and fiber technology are concerned. The carding result, that is, the cleaning, nep-formation and fiber shortening is to a large measure dependent from the carding clearance, that is, the distance between the clothing of the main carding cylinder and the clothing of the traveling or stationary flat bars. The guidance of air about the main carding cylinder and the heat removal are also dependent from the distance between the clothing of the main carding cylinder and the facing clothed or even non-clothed surfaces, such as a waste separating mote knife or cover elements of the machine. The extent of the distances depend from different, partially opposed effects. The wear of cooperating clothings leads to an enlargement of the carding clearance which results in an increase of the nep number and a decrease of the fiber shortening. An increase in the carding cylinder rpm, for example to increase the cleaning effect, causes, because of centrifugal forces, an enlargement of the carding cylinder, including its clothing and thus a decrease in the carding clearance results. The carding cylinder also expands and thus the carding clearance decreases because of the temperature increase in case a large quantity of fiber is processed or particular fiber types, for example, chemical fibers are handled.
[0004] In practice, during assembly of a carding machine, first the flat bars are installed and then the distance between the clothing points of the carding cylinder clothing and the clothing points of the flat bar clothings is determined by gauges. Such a distance is measured, for example, at every other flat bar, and an average value is formed from the measured values. The flat bars of a flat bar set regularly have different heights so that the distances are accordingly different. For changing the distance between the points of the flat bar clothings and the points of the main carding cylinder clothing, that is, to set a predetermined carding clearance, the position of the flexible bend (carrying the sliding guide for the flat bars) is radially adjusted at several locations by means of set screws. Thus, by changing the position of the sliding guide, the radial position of the flat bars is altered and, as a result, the distance between the clothings of the flat bars and the main carding cylinder is set.
[0005] An adjustment of the flexible bends as outlined above is complicated, time-consuming and requires skill and experience. Further, the geometry of the flexible bend depends from the number of the circumferentially distributed set screws. It is a further drawback that the entire flexible bend cannot be adjusted in one step. It is a particular disadvantage that the differences in the height positions of the flat bars are included in the measurements. Because of these height differences and the use of a plurality of circumferentially distributed set screws, the carding clearance cannot be set in a desired manner.
[0006] In a known arrangement, as described, for example, in European Patent No. 801 158 a sensor is provided with which the working distance of the carding clothings (also termed as “carding clearance”) can be measured, that is, the effective distance of the points of a clothing from a machine component facing the clothing can be determined. Such a machine component may also have a clothing but may also be, for example, a cover element provided with a guiding surface. The sensor is configured particularly for measuring the working distance between the carding cylinder and the flat bars of a traveling flats assembly. Such a working distance changes as the wear increases. By means of an optical instrument the carding clearance between the carding cylinder clothing and the flat bar clothings is to be sensed from the side of the working region. It is a disadvantage of this arrangement that the change of the carding clearance gives no indication to what extent the change is to be traced back to the different flat bars.
SUMMARY OF THE INVENTION
[0007] It is an object of the invention to provide an improved device of the above-outlined type from which the discussed disadvantages are eliminated and which, in particular, sets the carding clearance in a simple and time-saving manner.
[0008] This object and others to become apparent as the specification progresses, are accomplished by the invention, according to which, briefly stated, the fiber processing machine includes a roll having a circumferential surface provided with a first clothing having clothing points; a counter member having a surface provided with a second clothing cooperating with the first clothing and having clothing points; and a device for setting a clearance between the clothing points of the first and second clothings. The device includes an arrangement for approaching the roll and the counter member to one another until the clothing points of the first and second clothings contact and for moving away the roll and the counter member from one another until the clothing points of the first and second clothings assume a desired clearance. The device further has an arrangement for emitting a signal when the clothing points of the first and second clothings contact one another.
[0009] The measures according to the invention provide for a very accurate setting of the carding clearance in a simple and time-saving manner. It is a particular advantage of the invention that the setting is carried out without changing the shape of the flexible bend and the sliding guide; as a result, the previously uniformly and precisely set flexible bend and sliding guide retain their shape. It is a further advantage that the setting of a particularly narrow carding clearance is possible. This is of significance since the smaller the carding clearance, the better the carding effect.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] [0010]FIG. 1 is a schematic side elevational view of a carding machine incorporating the invention.
[0011] [0011]FIG. 2 is a fragmentary side elevational view of a traveling flats assembly.
[0012] [0012]FIGS. 3 a , 3 b and 3 c are fragmentary side elevational views of a traveling flats assembly illustrating the displacement of the flat bars before, during and after contact between the clothing of a flat bar and the clothing of the main carding cylinder.
[0013] [0013]FIG. 4 a is a schematic side elevational view of a traveling flats assembly, also illustrating the flexible bend and a shiftable slide guide.
[0014] [0014]FIG. 4 b is a view similar to FIG. 4 a showing the slide guide shifted in the direction A for radially repositioning the flat bars.
[0015] [0015]FIG. 5 is a schematic side elevational view of a device for shifting the slide guide.
[0016] [0016]FIGS. 6 and 6 a are schematic views of an embodiment of a device for determining a contact between clothing points.
[0017] [0017]FIG. 7 a is a schematic side elevational view of a flexible bend having a series of set screws.
[0018] [0018]FIG. 7 b is a sectional view taken along line 7 b - 7 b of FIG. 7 a.
[0019] [0019]FIG. 8 is a block diagram of an electronic control and regulating device.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0020] [0020]FIG. 1 illustrates a carding machine CM which may be for example, an EXACTACARD DK 803 model, manufactured by Trützschler GmbH & Co. KG, Mönchengladbach, Germany. The carding machine CM has a feed roller 1 , a feed table 2 cooperating therewith, licker-ins 3 a , 3 b , 3 c , a main carding cylinder 4 having a rotary axis M, a doffer 5 , a stripping roll 6 , crushing rolls 7 , 8 , a web guiding element 9 , a sliver trumpet 10 , calender rolls 11 , 12 , a traveling flats assembly 13 , having flats 14 , a coiler can 15 and a sliver coiler 16 .
[0021] Turning to FIGS. 2, 5 and 7 a , a flexible bend 17 is mounted by screws 32 on either side of the carding machine, laterally of the machine frame. The flexible bend 17 is provided with a plurality of set screws 31 . The flexible bend 17 has a convex upper face 17 a and an underside 17 b . The upper face 17 a of the flexible bend 17 supports a slide guide 20 , made, for example, of a low-friction synthetic material. The slide guide 20 has a convex upper surface 20 a and a concave lower surface 20 b . The concave lower surface 20 b lies on the convex upper surface 17 a and may slide thereon as indicated by the arrows A, B. The flat bars 14 have at opposite ends (spaced from one another parallel to the cylinder axis M) a flat bar head 14 a from which extend two steel pins 14 b adapted to glide on the convex upper surface 20 a of the slide guide 20 in the direction of the arrow C. The underface of each flat bar 14 carries a flat bar clothing 18 . The circle circumscribed on the flat bar clothings 18 is designated at 21 . The carding cylinder 4 has along its circumference a cylinder clothing 4 a such as a sawtooth clothing. The circle circumscribed about the cylinder clothing 4 a is designated at 22 . The clearance between the circles 21 and 22 is designated at d and amounts to, for example, 0.20 mm. The clearance between the convex upper surface 20 a of the slide guide 20 and the circle 22 is designated at e. The convex upper surface 20 a has a radius r 1 and the circle 22 has a radius r 2 . The radii r 1 and r 2 intersect in the rotary axis M of the carding cylinder 4 .
[0022] [0022]FIGS. 3 a , 3 b and 3 c show, to an exaggerated extent for better understanding, the change of the distances between the clothings 18 of the flat bars 14 and the clothing 4 a of the carding cylinder 4 .
[0023] [0023]FIG. 3 a shows the initial position of the flat bars 14 ′, 14 ″, 14 ′″ after their positioning on the upper face 20 a of the slide guide 20 . For manufacturing reasons the respective distances a 1 , b 1 and c 1 are different between the respective clothings 18 a , 18 b and 18 c , on the one hand and the cylinder clothing 4 a , on the other hand. For example, the distance a 1 between the clothing 18 a of the flat bar 14 ′ and the cylinder clothing 4 a is smaller than the distance b 1 (for example, {fraction (1/100)} inch) between the clothing 18 b of the flat bar 14 ″ and the cylinder clothing 4 a , whereas the distance cl between the clothing 18 c of the flat bar 14 ′″ and the cylinder clothing 4 a is greater than the distance b 1 .
[0024] According to FIG. 3 b , the flat bars 14 ′, 14 ″ and 14 ′″ are slowly shifted radially to the carding cylinder 4 in the direction D until the points of the clothing 18 a (having the smallest clearance a 1 according to FIG. 3 a ) and the cylinder clothing 4 a are just in contact with one another, that is, the clearance a 2 is zero. Such a minimal contact is harmless even if the carding cylinder 4 rotates. The contact between a flat bar clothing 18 and the cylinder clothing 4 a is sensed by a device 23 as will be described in conjunction with FIGS. 6, 6 a.
[0025] Subsequently, as shown in FIG. 3 c , the flat bars 14 ′, 14 ″ and 14 ′″ are shifted radially in the direction E in such a manner that the points of the clothing 18 a of the flat bar 14 ′ and the cylinder clothing 4 a are just separated from one another, that is, a clearance a 3 is obtained. The clearance a 3 should be as small as safely possible, for example, between {fraction (1/1000)} and {fraction (2/1000)} inch. As a result of the above-described manipulation the clearances b 3 and c 3 are as small as possible. A small distance a 3 , b 3 and c 3 , that is, a possibly small carding clearance is desirable for achieving superior carding results.
[0026] In FIGS. 4 a and 4 b , shifting of the slide guide 20 on the flexible bend 17 in the direction of the arrow A is shown. Due to the wedge shape of the slide guide 20 , its circumferential displacement, for example, in the direction of the arrow A, will increase the clearance b 1 , b 2 and b 3 between the respective flat clothings 18 a , 18 b and 18 c on the one hand and the cylinder clothing 4 a , on the other hand; that is, the clearance between the circles 21 and 22 (FIG. 2) is increased. Thus, by shifting the slide guide 20 in the direction A, the flat bars 14 are lifted from their position shown in FIG. 4 a in the direction E into the position illustrated in FIG. 4 b . The flat bars 14 are slowly moved between the end roller 13 a and the end roller 13 b of the traveling flats assembly 13 by a non-illustrated belt in the direction C (FIG. 2) and are reversed as they travel on the end roller 13 b to be moved on the idling side of the traveling flats assembly in the rearward direction F.
[0027] As shown in FIG. 5, a carrier element 26 affixed to the slide guide 20 is coupled with a toothed rack 27 a engaging a gear 27 b which is rotatable in the directions O, P and which is rotated by a drive, such as a reversible motor 28 . The device can circumferentially shift the slide guide 20 in the direction of the arrow A or B. The drive 28 is coupled with an inputting device 29 with which the desired, smallest carding gap a 3 , for example, {fraction (3/1000)} inch may be set as a desired magnitude. Such a setting may also be performed by an electronic control and regulating device 33 (FIG. 8) which has a desired value memory and/or an inputting device.
[0028] As shown in FIG. 6, a device 23 is coupled to the flat bar clothings 18 and the cylinder clothing 4 a in an electric circuit for emitting a signal when the clothing 18 of a flat bar 14 contacts the clothing 4 a of the carding cylinder. Thus, the clothing points of the clothings 4 a and 18 act as electric contacts. The device 23 may be structured such that the clothing 4 a of the cylinder 4 whose bearings are electrically insulated from the frame, is connected with one pole of an electric current source 24 , whereas the other pole is coupled to the machine frame in a non-illustrated manner, so that the flat bars 14 are coupled with that pole of the current source. The electric circuit contains an indicating device 25 which shows whether or not a contact is present between the clothing points. Such a contacting may also be detected by measuring the electric resistance in the circuit, or by an arrangement based on sound detection. Or, as other alternatives of contact-sensing, the acceleration of the traveling flats is sensed or, in case of a stationary carding cylinder 4 , a motion of the carding cylinder as entrained by the contacting traveling flat bar is observed.
[0029] Turning to FIG. 7 a , a circumferential groove 30 is provided in the flexible bend 17 . The slide guide 20 which is composed of an elastic, low-friction synthetic material is, as shown in FIG. 7 b , accommodated in the groove 30 such that one part of the slide guide 20 is situated within the groove 30 whereas another part projects beyond the convex upper surface 17 a of the flexible bend 17 . The slide guide 20 is shiftable within the groove in the direction of the arrows A, B so that the concave lower face 20 b slides on the bottom surface 25 a of the groove. The side faces 25 b and 25 c of the groove constitute lateral guides for the slide guide 20 . By means of the set screws 31 first the flexible bend 17 is set, while maintaining its correct shape, to a carding clearance of, for example, {fraction (6/1000)} inch. It is only with the device shown in FIGS. 4 a , 4 b and 5 that the carding clearance may be reduced to such an extent that the flat bar clothing 18 which originally has the smallest distance from the cylinder clothing 4 a , contacts the latter. Subsequently, the carding clearance may be set very accurately to a desired magnitude with the device shown in FIGS. 4 a , 4 b and 5 .
[0030] [0030]FIG. 8 illustrates an electronic control and regulating device 33 , such as a microcomputer to which there are connected an inputting device 34 for the desired carding clearance, the drive 28 for rotating the gear 27 b , the device 23 to detect a contact between the flat bar clothing 18 and the cylinder clothing 4 a , the indicating device 25 , the inputting device 29 and a switching element 35 for actuating the drive 28 .
[0031] 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 fiber processing machine includes a roll having a circumferential surface provided with a first clothing having clothing points; a counter member having a surface provided with a second clothing cooperating with the first clothing and having clothing points; and a device for setting a clearance between the clothing points of the first and second clothings. The device includes an arrangement for approaching the roll and the counter member to one another until the clothing points of the first and second clothings contact and for moving away the roll and the counter member from one another until the clothing points of the first and second clothings assume a desired clearance. The device further has an arrangement for emitting a signal when the clothing points of the first and second clothings contact one another. | 3 |
BACKGROUND OF THE INVENTION
Pigfish ( Orthopristis chrysoptera )
[0001] Pigfish are popular baitfish that can grow to a length of 12 to 15 inches. Pigfish are common on the South Atlantic and Gulf coasts of the United States. The range is north to Long Island and south to the mouth of the Rio Grande River. Pigfish are particularly abundant along the Carolina coast.
[0002] Pigfish are members of the grunt family (Haenulidae) which are noted for the rasping or grunting sounds they make in their throat when captured on a hook or otherwise disturbed. The grunt resembles the sound made by a pig and is produced by means of a pair of movable muscles in the throat covered with small recurved teeth, known as pharyngeal teeth.
[0003] Fishermen have very good results using pigfish as bait to catch saltwater Seatrout as well as other larger fish. Fishermen will testify that the grunting sound made by Pigfish seems to attract the catch very effectively. Applicant notes that on a recent fishing trip he observed a fisherman bait his hook with a live pigfish that was grunting. After only two minutes of being in the water, the fisherman caught a six pound saltwater Seatrout.
[0004] Unfortunately, however, a pigfish does not live very long while baited. Once it dies, its ability to grunt is gone and it loses much of its unique effectiveness as bait.
Small Lightweight Sound Recording and Playback Device
[0005] FIGS. 2-3 show a prior art portable small, lightweight sound recording and playback device 2 . Recording and playback devices similar to recording and playback device 2 are available from Voice-Express Corporation with offices in Westport, Conn. As shown in FIG. 1 , four batteries 3 are mounted on printed circuit board (PCB) 1 and provide power to programmable playback/record integrated circuit chip 4 . Playback/Record/Off switch 7 is also mounted to PCB 1 . PCB 1 is mounted inside aluminum casing 8 . A top view of casing 8 is shown in FIG. 2 and a side view is shown in FIG. 3 . Aluminum casing 8 is approximately 1¾ inch in diameter and has a cutout section to allow access to switch 7 . Small holes 9 are in the top of casing 8 to allow sound to travel to microphone 5 and sound to travel from speaker 6 .
[0006] Sound recording and playback device 2 is commonly placed in a child's toy such as child's toy 11 , as shown in FIG. 4 . A child can record a message onto playback/record chip 4 by moving switch 7 to “record”. Digital data representative of the child's message is stored on chip 4 . When switch 7 is moved to “play” electrical signals representative of the child's message is transmitted from chip 4 to speaker 6 where the speaker converts the electrical signals to sound for the child to hear. Sound recording and playback device 2 is capable of recording a 20 second message. Chip 4 is programmed to repeat the message until switch 7 is moved to “off”.
Speakers
[0007] Speakers are known in the prior art and are electro-acoustic transducers that convert electrical signals into sounds loud enough to be heard at a distance.
Underwater Speakers
[0008] Waterproof underwater speakers are known. For example, synchronized swimmers will perform to music being played through underwater speakers mounted under the waterline on the side of a pool. Also, deep sea divers can communicate through underwater telephones that utilize underwater speakers to transmit sound.
[0009] What is needed is a better fishing lure.
SUMMARY OF THE INVENTION
[0010] The present invention provides a sound fishing lure with a speaker system. A power source provides power to an integrated circuit chip programmed to produce electronic signals that when transmitted to the speaker produce animal sounds. Fish hearing the sounds are attracted to the fishing lure. In a preferred embodiment, the chip is programmed to record and playback actual animal sounds. In another preferred embodiment, the recorded sound is that of a pigfish grunting.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIGS. 1-4 show a prior art sound recording a playback device.
[0012] FIGS. 5-6 show a first preferred embodiment of the present invention.
[0013] FIGS. 7-9 show a second preferred embodiment of the present invention.
[0014] FIGS. 10-12 show a third preferred embodiment of the present invention.
[0015] FIG. 13 shows a fourth preferred embodiment of the present invention.
[0016] FIG. 14 shows a fifth preferred embodiment of the present invention.
[0017] FIG. 15 shows a sixth preferred embodiment of the present invention.
[0018] FIG. 16 shows a seventh preferred embodiment of the present invention.
[0019] FIG. 17 shows an eighth preferred embodiment of the present invention.
[0020] FIGS. 18-19 show a ninth preferred embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
First Preferred Embodiment
[0021] A first preferred embodiment of the present invention is shown in FIGS. 5-6 . In FIG. 5 , PCB 1 with record/playback integrated circuit chip 4 has been placed inside thin sealable waterproof plastic bag 10 . Plastic bag 10 has then been sealed tight along seal 12 . Prior to placing PCB 1 into plastic bag 10 , a user recorded a 10 second recording of the sound of a pigfish grunting onto chip 4 .
[0022] In FIG. 6 , plastic bag 10 ( FIG. 5 ) with PCB 1 has been placed inside casing 8 of sound lure 30 . Casing 8 has been modified to include eyelets 13 and eyelet 14 . Hooks 15 have been attached to eyelets 13 and line 16 has been attached to eyelet 14 . Switch 7 has been moved to the play position.
Utilization of the First Preferred Embodiment
[0023] To use the first preferred embodiment, a user merely moves switch 7 to the play position. The sound of a pigfish grunting will then be continuously repeated until batteries 4 ( FIG. 1 ) lose their charge or until switch 7 is moved to the off position.
[0024] To catch a fish, the user throws sound lure 30 into the water. Plastic bag 10 is watertight to protect PCB 1 and its components from the water. Also, plastic bag 10 is thin enough so that the sound of the pigfish grunting emitted from speaker 6 can be heard through the plastic. The sound of the pigfish grunting will attract fish that will then be caught on hooks 15 after striking at sound lure 30 .
Second Preferred Embodiment
[0025] A second preferred embodiment is shown in FIGS. 7-9 .
[0026] In the second preferred embodiment, it is not necessary for the fisherman to record onto chip 4 the sound of a pigfish grunting. Rather, the manufacturer of the lure programs the chip to produce the animal sounds. This may be done by recording and reproducing the animal sounds or the chip could be programmed to simulate the animal sounds. The recorded pigfish sound could be a recording of an actual pigfish grunting or it could be a recording of a human being imitating a pigfish grunting.
[0027] In FIG. 7 , batteries 3 , speaker 6 , on/off switch 25 and record/playback chip 4 has been mounted onto PCB 20 . Preferably, the manufacturer of sound lure 22 has prerecorded onto record/playback chip 4 a 10 second recording of a pigfish grunting. Chip 4 is programmed to automatically repeat the playing of the pigfish grunting whenever on/off switch 25 is switched to the “on” position.
[0028] In FIGS. 8-9 , PCB 1 has been placed inside casing 18 of sound lure 22 . Casing 18 is preferably fabricated from a corrosion resistant hard plastic. Top portion 22 a of casing 18 is threaded onto bottom portion 22 b to form a watertight seal. Speaker cover portion 22 c is sufficiently thin so that sound emitted from speaker 6 can be heard through speaker cover portion 22 c.
[0029] Casing 18 includes eyelets 13 and eyelet 14 . Hooks 15 have been attached to eyelets 13 and line 16 has been attached to eyelet 14 . Switch 25 has been moved to the “on” position.
Utilization of the Second Preferred Embodiment
[0030] To use the second preferred embodiment, a user merely moves switch 25 to the “on” position. The sound of a pigfish grunting will then be continuously repeated. To catch a fish, the user throws sound lure 22 into the water. The sound of the pigfish grunting will attract fish that will then be caught on hooks 15 after striking at sound lure 22 .
Third Preferred Embodiment
[0031] A second preferred embodiment is shown in FIGS. 10-12 .
[0032] As with the second preferred embodiment, with the third preferred embodiment it is not necessary for the fisherman to record onto programmable chip 4 the sound of a pigfish grunting. Rather, this step has already been accomplished by the manufacturer. FIG. 10 shows an exploded view of the third preferred embodiment. Speaker 50 , programmable chip 4 and battery 52 are placed inside bottom section 55 (see also FIG. 11 ). Top section 54 is then threaded onto bottom section 55 . Compression spring 53 holds internal components 50 , 4 and 52 in place. On/off switch 56 completes the connection between battery 52 and chip 4 .
[0033] In FIG. 11 , battery 52 , speaker 50 and chip 4 have been placed inside bottom section 55 . Preferably, the manufacturer of sound lure 60 has prerecorded onto record/playback chip 4 a 10 second recording of a pigfish grunting. Chip 4 is programmed to automatically animal the playing of the pigfish grunting whenever on/off switch 56 is switched to the “on” position.
[0034] In FIG. 12 , top section 54 has been threaded onto bottom section 55 to form a watertight seal. Top section 54 and bottom section 55 are preferably fabricated from a corrosion resistant hard plastic. Bottom section 55 is sufficiently thin so that sound emitted from speaker 50 can be heard through sound lure 60 .
[0035] Sound lure 60 includes eyelets 61 and 62 . Hook 15 has been attached to eyelet 61 and line 16 has been attached to eyelet 62 . Switch 56 has been moved to the “on” position.
Utilization of the Third Preferred Embodiment
[0036] To use the third preferred embodiment, a user merely moves switch 56 to the “on” position. The sound of a pigfish grunting will then be continuously repeated. To catch a fish, the user throws sound lure 60 into the water. The sound of the pigfish grunting will attract fish that will then be caught on hook 15 after striking at sound lure 60 .
Fourth Preferred Embodiment
[0037] FIG. 13 shows a fourth preferred embodiment of the present invention. In the fourth preferred embodiment, sound lure 22 preferably has one eyelet 13 . Line 70 connects sound lure 22 to fishing lure 71 .
[0038] To use the fourth preferred embodiment, a user merely moves switch 25 to the “on” position. The sound of a pigfish grunting will then be continuously repeated.
[0039] To catch a fish, the user throws sound lure 22 into the water. The sound of the pigfish grunting and the sight of lure 71 will attract fish that will then be caught on either hook 15 .
Fifth Preferred Embodiment
[0040] FIG. 14 shows a fifth preferred embodiment of the present invention. In the fifth preferred embodiment, sound lure 22 preferably has one eyelet 13 . Lure 71 is connected to sound lure 22 at eyelet 13 .
[0041] As with the fourth preferred embodiment, to use the fifth preferred embodiment, a user merely moves switch 25 to the “on” position. The sound of a pigfish grunting will then be continuously repeated.
[0042] To catch a fish, the user throws sound lure 22 into the water. The sound of the pigfish grunting and the sight of lure 71 will attract fish that will then be caught on either hook 15 .
Sixth Preferred Embodiment
[0043] FIG. 15 shows a sixth preferred embodiment of the present invention. In the sixth preferred embodiment, sound lure 22 preferably has one eyelet 13 . Hook 15 is connected to eyelet 13 . Baitfish 80 is hooked on hook 15 . Preferably, baitfish 80 is living. Also, preferably baitfish 80 is a pigfish.
[0044] As with the fourth preferred embodiment, to use the sixth preferred embodiment, a user merely moves switch 25 to the “on” position. The sound of a pigfish grunting will then be continuously repeated.
[0045] To catch a fish, the user throws sound lure 22 with baitfish 80 into the water. The sound of the pigfish grunting from sound lure 22 and the sight of baitfish 80 will attract fish that will then be caught on either hook 15 . If the baitfish is a living pigfish, then it should make its own grunting noise to combine with the grunting noise from sound lure 22 . The combined grunting noises will serve to attract fish. Furthermore, the sight of an actual pigfish should make attacking fish even more eager to take the bait since the noise that is being emitted from sound lure 22 is a pigfish grunting noise.
Seventh Preferred Embodiment
[0046] FIG. 16 shows a seventh preferred embodiment of the present invention. In the seventh preferred embodiment, sound lure 91 is shaped and painted to look similar to a pigfish and serves as a waterproof encasing to internal components 50 , 4 , and 521 . As described in reference to the third preferred embodiment, speaker 50 emits the sound of a pigfish grunting. This sound is transmitted through the side of sound lure 91 and attracts fish to the lure. On/off switch 56 is mounted to the side of sound lure 91 . Hooks 15 are connected to sound lure 91 .
[0047] As with the fourth preferred embodiment, to use the seventh preferred embodiment, a user merely moves switch 56 to the “on” position. The sound of a pigfish grunting will then be continuously repeated.
[0048] To catch a fish, the user throws sound lure 91 into the water. The sound of the pigfish grunting and the sight of sound lure 91 will attract fish that will then be caught on either hook 15 .
Eighth Preferred Embodiment
[0049] FIG. 17 shows an eighth preferred embodiment of the present invention. The eighth preferred embodiment is very similar to the seventh preferred embodiment, except that the eighth preferred embodiment is in the general shape of fish and is not shaped to look exactly like a pigfish. The eighth preferred embodiment recognizes that the sound lure can still be effective if it is shaped like an ordinary fish.
[0050] In the eighth preferred embodiment, internal components 50 , 4 , and 52 are mounted inside sound lure 101 . As described in reference to the third preferred embodiment, speaker 50 emits the sound of a pigfish grunting. This sound is transmitted through the side of sound lure 101 and attracts fish to the lure. On/off switch 56 is mounted to the side of sound lure 91 . Hooks 15 are connected to sound lure 91 .
[0051] As with the fourth preferred embodiment, to use the seventh preferred embodiment, a user merely moves switch 56 to the “on” position. The sound of a pigfish grunting will then be continuously repeated.
[0052] To catch a fish, the user throws sound lure 101 into the water. The sound of the pigfish grunting and the sight of sound lure 101 will attract fish that will then be caught on either hook 15 .
Ninth Preferred Embodiment
[0053] A ninth preferred embodiment is shown in FIGS. 18 and 19 . The ninth preferred embodiment is similar to the earlier described embodiments with the exception that speaker 90 is an underwater speaker and is not covered completely by the casing of sound lure 92 . By utilizing an underwater speaker, the sound of the pigfish grunting is louder because it does not have to travel through the casing. The underwater speaker is exposed directly to the water. By utilizing the ninth preferred embodiment, the sound will travel further and potentially attract more fish. The ninth preferred embodiment is utilized in a manner similar to that described above in reference to the earlier preferred embodiments.
Other Preferred Embodiments
[0054] Applicant believes that the sound of a pigfish grunting attracts larger fish because a pigfish is part of the normal diet of larger fish and the pigfish naturally makes the grunting sound when disturbed. Therefore, larger fish hearing the sound may conclude that a pigfish is in trouble and may be easy prey.
[0055] In addition to the sound of a pigfish grunting, there may be sound recordings of other animals that likewise attract larger fish. For example, there are other members of the grunt family other than pigfish. For example, the porkfish ( Anisotremus virginicus ) is a member of the grunt family and also makes a grunting noise when disturbed. Therefore, a sound of a porkfish grunting could be used to attract a larger fish. Likewise, the Atlantic croaker ( Micropogonias undulatus ) is a popular baitfish for catching grouper. The Atlantic croaker makes a distinctive croaking noise by vibrating its internal air-filled swim bladder. The croaking sound is similar to a muffled booming noise. A sound lure that emits a sound of the Atlantic croaking making its noise would be useful for catching fish. Also, the sound of a seal barking could be a used to attract sharks. Sharks have excellent hearing capability and seals are part of their normal diet. Other recorded animal sounds that when played back would be useful in attracting fish include: the sound of a bullfrog, the sound of a cricket, or the sound of a mouse squeaking.
[0056] Although the above-preferred embodiments have been described with specificity, persons skilled in this art will recognize that many changes to the specific embodiments disclosed above could be made without departing from the spirit of the invention. Therefore, the attached claims and their legal equivalents should determine the scope of the invention. | A sound fishing lure with a speaker system. A power source provides power to an integrated circuit chip programmed to produce electronic signals that when transmitted to the speaker produce animal sounds. Fish hearing the sounds are attracted to the fishing lure. In a preferred embodiment, the chip is programmed to record and playback actual animal sounds. In another preferred embodiment, the recorded sound is that of a pigfish grunting. | 0 |
RELATED APPLICATION(S)
[0001] The present application is a non-provisional application of U.S. Provisional Patent Application Ser. No. 61/512,880 filed Jul. 28, 2011 entitled “LASER ASSISTED NAIL AVULSION”, Attorney Docket No. CTI-2002-P, which is related to U.S. Ser. No. 12/841,110 filed Jul. 21, 2010, entitled “TREATMENT OF MICROBIAL INFECTIONS USING HOT AND COLD TREATMENT SHOCK AND PRESSURE”, Attorney Docket No. CTI-2001, which is a non-provisional application of U.S. Provisional Patent Application Ser. No. 61/227,739 filed Jul. 22, 2009 entitled “TREATMENT OF MICROBIAL INFECTIONS USING HOT AND COLD THERMAL SHOCK AND PRESSURE”, Attorney Docket No. CTI-2001-P, which is incorporated herein by reference in its entirety, and claims any and all benefits to which it is entitled therefrom.
FIELD OF THE INVENTION
[0002] This invention relates to the treatment and inactivation of microbial infections. Fungal infections of the toenail are treated by removing the infected nail plate and subsequently applying a source of thermal energy to the nail bed to inactivate residues of the microbe and to improve the healing of the wound. This laser assisted therapy is more efficient, safer, and more effective than previous methods of using nail surgery or laser treatment of the nail separately.
BACKGROUND OF THE INVENTION
[0003] As many as 700 million people worldwide suffer from onychomycosis or toenail fungal infections. There are many systemic, topical and surgical treatments available to treat this disease but none are truly efficacious and several have severe potential side effects. A need exists for a better cure for this widespread disease.
[0004] Optical and laser treatment of toenail fungus has been known for many years. In particular, UV light in the 100-400 nm range has proven to be able to inactivate many pathogens including the ones responsible for onychomycosis in non-thermal dosages. Unfortunately UV light has difficulty penetrating the toenail and can cause side effects in the dermis. UV light is not considered to be a successful treatment modality despite a great deal of research.
[0005] U.S. Pat. No. 6,723,090, issued Apr. 20, 2004 to Altshuler et al., U.S. Pat. No. 7,220,254, issued May 22, 2007 to Altshuler et al., US Publication No. 2006/0212098, published Sep. 21, 2006 to Demetriou et al., Non-patent publication “Laser treatment for toenail fungus”, Proc. of SPIE Vol. 7161 published 2009 by Harris et al. and others have proposed using infrared radiation to thermally inactivate toenail fungus. Infrared radiation penetrates the toenail much better than UV and it has been shown that the fungus can be inactivated by raising the temperature of the pathogen to about 50 oC. The problem associated with this method is that achieving the inactivation temperature in the nail bed risks damaging the surrounding dermal tissue, especially the matrix where the nail actually grows. In addition this prior art allows the use of infrared radiation with high hemoglobin absorption. Hemoglobin absorbing wavelengths can coagulate capillaries in the proximal fold and permanently damage the toenail.
[0006] U.S. Pat. No. 6,723,090, issued Apr. 20, 2004 to Altshuler et al., U.S. Pat. No. 7,220,254, issued May 22, 2007 to Altshuler et al. propose to use a cooling modality to protect the toenail during infrared laser irradiation to target the nail bed and he suggests that a pulsed laser may be superior to a continuous one.
[0007] US Publication No. 2006/0212098, published Sep. 21, 2006 to Demetriou et al. suggests the use of pulsed cryogen cooling, which is also described in U.S. Pat. No. 5,814,040, issued Sep. 29, 1998 to Nelson et al., to protect the toe from excessive heating and to use the process of selective photothermolysis, which is disclosed in non-patent publication “Selective Photothermolysis: Precise Microsurgery by Selective Absorption of Pulsed Radiation”, published on Science, 220:524-527, 1983 by Anderson et al., to choose the correct pulse length to match the thermal properties of the fungus itself Methods taught respectively in U.S. Pat. No. '090, '254 to Altshuler et al. and US Publication '098 by Demetriou et al. all require relatively high target temperatures that can damage the matrix and teach to cool only the surrounding tissue. The above-mentioned methods may cause permanent damage to sensitive areas.
[0008] U.S. Pat. No. 6,090,788, issued Jul. 18, 2000 to Lurie teaches that light-absorbing substances may be considered to induce and enhance selective photothermal damage. The problem and shortcoming with this method is the difficulty in getting the substance infused to the proper areas and the high temperatures required to inactivate the microbe. Damage to the surrounding tissue is likely to happen by using this method.
[0009] Capon and others have published non patent descriptions of the wound healing and scar reduction capabilities of thermal laser energy when applied to a surgical site immediately pre and post op. The mechanism of action of this wound healing effect is postulated to be the activation of a heat shock protein.
[0010] Nail removal or avulsion has been used to treat badly infected toenails but without success. The fungal infection is not completely eliminated even with the removal of the nail and the area usually becomes re infected even with the application of topical antifungal medications and good foot hygiene. It is not obvious that laser treatment after nail avulsion would be of any benefit. Only after months of experimentation with laser power settings did the Inventors discover that there is a level of laser energy and method of application that simultaneously provides hemostasis, microbe inactivation, and wound healing. Laser energy at too low a power setting is ineffective and the fungus returns. Laser power at too high a setting will ablate the tissue and permanently injure the patient or kill the nail matrix and prevent re growth of the nail plate.
[0011] Chato has shown that heat alone is effective in inactivating fungus if it can be held at 50 deg C. for about 5 min It is almost impossible to do this in vivo as surrounding tissue will be destroyed along with the fungus. Others have tried to heat the fungus through the nail with limited success. One device made by PinPointe, Inc. is able to only show a partial clearing of the nail after several laser treatments through the nail. This device is applied through the nail and is done without any anesthesia preventing therapeutic temperature levels from being achieved safely. This device also does not monitor surface temperature so the precise therapeutic temperature cannot be safely achieved. Clinical results with this device have shown only a 20% reduction in the infected area of the nail at 12 months post op.
ADVANTAGES AND SUMMARY OF THE INVENTION
[0012] The present invention makes the treatment of inaccessible microbial infections more effective and efficient than previously taught in the prior art.
[0013] The goal of the present invention is to improve efficacy of treatment of nail disease. Nail Avulsion alone is about 50% effective and laser treatment of nail bed promotes collagen formation and wound healing. Combined treatment is more effective than avulsion alone.
[0014] This invention is composed of the following steps:
a. Anaesthetizing the toenail with a local anesthesia. b. Removing the overlying nail plate of the toenail to expose the infection. c. Irradiating the open wound with sufficient energy to cauterize broken capillaries. d. Irradiating the open wound to desiccate the infection, reducing microbe activity. e. Irradiating the exposed fungal infection to thermal energies capable of inactivating the microbes. f. Thermally injuring the exposed tissue to stimulate a wound healing effect but with energy low enough to preserve the nail matrix.
[0021] The present invention utilizes a thermal feedback sensor and laser controller to precisely control the energy delivered to the site. Without a thermal feedback mechanism it is not possible to maintain a treatment surface temperature that will cauterize, inactivate, desiccate, and stimulate, while preserving the ability to re grow a healthy new nail.
[0022] The present invention utilizes a laser that is only partially absorbed in the target tissue. Laser energy that is absorbed too shallow will not penetrate deep enough to stimulate a wound healing effect. Laser energy that penetrates too deeply will not heat the surface tissue hot enough to inactivate the microbes and may damage underlying structure including the matrix area that generates new nail growth. The present invention uses a laser wavelength that is absorbed in water which assists in desiccation of the infections and provides better hemostasis of ruptured capillaries.
[0023] The present invention utilizes a cooling mechanism that will cool surrounding tissue and prevent collateral damage during laser irradiation.
[0024] The present invention adds highly absorbing dyes and/or metallic nanoparticles such as gold nanoparticles GNP to enhance the absorption by the targeted fungus. Furthermore, the use of GNP causes photothermal micro-bubbles PTMB at the surface of the GNP, which in turn provide an effective way of promoting non-thermal mechanical and localized inactivation of microbes. Prior art has not taught the use of GNP to inactivate living microbes. Prior art has only utilized GNP to physically ablate nonliving tissue such as plaque.
[0025] The present invention adds a photo active compound to the treatment site to accelerate the inactivation of the microbe. This compound can be Riboflavin or vitamin B, which will absorb UV light and become active to kill the fungus in the treatment area.
[0026] The present invention adds a topical antifungal that is delivered directly to the treatment site in conjunction with laser delivery and whose effect is enhanced by the thermal heating properties of the laser.
[0027] Thus, it is an object of the present invention to make the treatment of inaccessible microbial infections much more effective and efficient.
[0028] It is yet a further object of the present invention to provide treatment of microbial infections using laser energy transmitted via fiber optic laser delivery device.
[0029] It is yet a further object of the present invention to provide an improved method and apparatus for treatment of microbial infections of toenails, including onychomycosis.
BRIEF DESCRIPTION OF THE DRAWINGS
[0030] FIG. 1 is a representative illustration showing an embodiment of the apparatus and method of treatment of microbial infections using thermal inactivation and wound healing of exposed infections of the present invention 100 .
[0031] FIG. 2 is a representative illustration showing an embodiment of a transparent toe jacket 200 of the present invention 100 .
[0032] FIG. 3 is a representative illustration showing an embodiment of laser control system with cooling spray device devices and methods of the present invention 100 .
[0033] FIG. 4 is a representative illustration of laser assisted wound healing.
[0034] FIG. 5 is a representative illustration of laser assisted nail avulsion.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0035] The description that follows is presented to enable one skilled in the art to make and use the present invention, and is provided in the context of a particular application and its requirements. Various modifications to the disclosed embodiments will be apparent to those skilled in the art, and the general principals discussed below may be applied to other embodiments and applications without departing from the scope and spirit of the invention. Therefore, the invention is not intended to be limited to the embodiments disclosed, but the invention is to be given the largest possible scope which is consistent with the principals and features described herein.
[0036] It will be understood that in the event parts of different embodiments have similar functions or uses, they may have been given similar or identical reference numerals and descriptions. It will be understood that such duplication of reference numerals is intended solely for efficiency and ease of understanding the present invention, and are not to be construed as limiting in any way, or as implying that the various embodiments themselves are identical.
[0037] FIG. 1 is a representative illustration showing an embodiment of the apparatus and method of treatment of microbial infections using thermal inactivation and wound healing of the present invention 100 .
[0038] The present invention 100 uses an automatic target thermal feedback to precisely control the dosimetry of the laser 112 , or intense light or intense pulsed light IPL irradiation, to prevent damage to surrounding tissue and reduce pain. A non-contact thermal detector 137 , such as made by Raytek or equivalent, is built into a handpiece along with a lens to focus the laser delivery fiber optic 504 or a laser diode. The output of the non-contact thermal detector 137 is used to adjust the power output of the laser 112 to maintain a selected treatment temperature at the treatment site 102 .
[0039] A preferred embodiment of the present invention utilizes a 1320 nm continuous or pulsed laser 112 that is capable of delivering 2 to 5 watts of energy, or more or less, with continuous or pulsed cryogen cooling 140 . The energy is delivered from a handpiece that focuses the light into a 2-10 mm diameter spot on the treatment tissue, treatment site 102 . A non contact thermal sensor 137 detects the temperature of the treated spot and send a signal to the laser 112 control system which then adjusts the energy to maintain a pre selected target temperature at the spot. A continuous or pulsed cooling spray device 140 is incorporated into the handpiece to deliver a spray of coolant 502 to the target treatment spot 102 after each laser treatment interval.
[0040] It will be understood that the site of infection is associated with the nail 204 of the finger or toe 202 the nail has a plate 206 as well as a bed 208 .
[0041] Preferential absorption of laser energy 290 having a wavelength of 1320 nm to 1470 nm by the nail bed 206 of the infected toe or finger 204 results in a controlled elevation in temperature to a temperature effective at disinfection of the infected regions or areas without causing irreversible thermal damage to the infected nails.
[0042] FIG. 2 is a representative illustration showing an embodiment of a transparent toe jacket 200 of the present invention 100 . As best shown in FIG. 2 , fiber optic laser delivery system 220 comprises optical fibers as well as lens mechanism 222 , and optional filters, convertors or other beam modifiers which can be coupled to the toe 200 as desired.
[0043] FIG. 3 is a representative illustration showing an embodiment of laser control system with cooling spray device devices and methods of the present invention 100 . As described above, a preferred embodiment of the present invention utilizes a 1320 nm continuous or pulsed laser 112 that is capable of delivering 2 to 5 watts of energy, with continuous or pulsed cryogen cooling. The energy is delivered from a handpiece 300 that focuses the light into a 2-10 mm diameter spot on the target treatment spot 102 . The laser 112 control system adjusts the energy to maintain a pre selected target temperature at the spot. A continuous or pulsed cooling spray device is incorporated into the handpiece 300 to deliver a spray of coolant to the target treatment spot 102 after each laser treatment interval.
[0044] The laser and coolant delivery handpiece 300 can be the CoolTouch® TQ10 model handpiece or equivalent. In an embodiment, the handpiece 300 can deliver laser energy 290 at a wavelength of 1320 nanometers at a fluence rate of 24 Joules per square centimeter. The handpiece 300 with integrated continuous or pulsed cryogen cooling reduces the surface temperature for protection allowing the laser energy 290 to be effectively targeted. Cooling can be provided adjustably cooling to maximize patient comfort, safety and efficacy.
Treatment Agents
[0045] It will be understood that THE PRESENT INVENTION consists of applying liquid or gas directly to the target, i.e., to the infected nail. Furthermore, the liquid or gas may contain one of more of the following: pain reducing agent, antifungal agent, anti-microbial agent, antiseptic agent or disinfectant agent. It will be understood that there are a wide range of agents which are associated with pain reduction, anti-irritant, antifungal treatment, antimicrobial and antibiotic activity as well as antiseptic and disinfecting properties, the use of which is expressly contemplated herein.
[0046] Antifungal agents may include any antifungal agents useful in dermatological compositions. Examples of antifungal agents include, without limitation, Tea Tree oil and other naturally occurring oils and compounds, nystatin, ciclopirox and ciclopirox olamine, griseofulvin, itraconazole, fluconazole, ketoconazole, terbinafine, econazole, benzyl alcohol, undecylenic acid and salts thereof, benzyl benzoate and combinations thereof. Antifungal agents are well known in the art. One of ordinary skill in the art would understand, appreciate and recognize agents that are considered to be antifungal agents.
[0047] Antimicrobial agents may include any antimicrobial agents useful in dermatological compositions. Antimicrobial agents include, without limitation, benzoyl peroxide, povidone iodine, hexachlorphene, chlorhexidine, mupirocin, gentimycin, neomycin, bacitracin, polymixin, erythromycin, clindamycin, metronidazole, clarithromycin, silver sulfadiazine, dapsone, zinc pyrithione, cephalosporin, thymol, mafenide acetate, nitrofurazone, generators of nitric oxide benzyl alcohol, sulfamethoxazole, sulfasalazine, sulfasoxazole, acetylsulfasoxazole and combinations thereof. Antimicrobial agents are well known in the art. One of ordinary skill in the art would understand, appreciate and recognize agents that are considered to be antimicrobial agents.
[0048] Anti-irritants are well known in the art. One of ordinary skill in the art would understand, appreciate and recognize agents that are considered to be anti-irritants. Preferred anti-irritants include but are not limited to aloe vera gel, alpha bisabolol, allantoin, sorbitol, urea, lactic acid and salts, glucose derivatives, zinc acetate, zinc carbonate, zinc oxide, potassium gluconate, dimethicone, glycerin, petrolatum, lanolin, peramides, uric acid and salts, N-acetyl cysteine, and hydrocortisone.
[0049] Disinfectants are also well known in the art. One of ordinary skill in the art would understand, appreciate and recognize agents that are considered to be disinfectants. Preferred disinfectants include but are not limited to chlorine bleach or sodium hypochlorite
[0050] Antiperspirants are used post op to control moisture in the wound area. Preferred antiperspirants include over the counter under arm sprays such as.
Method Of Treatment
[0051] The following is taken from the CoolBreeze® (trademark) treatment guidelines for onychomycosis.
Patient Preparation:
[0000]
1. Remove all lotions and skin care products, making certain that the skin of the foot and nail bed are completely dry prior to treatment.
2. Local anesthetics are recommended for the CoolBreeze mode. The local anesthetic is administered by injection to each infected toe. Anesthetics allow therapeutic energy levels to be used with patient comfort.
3. Remove the infected nail using standard avulsion techniques. Scrape away any infected residue under the nail.
[0055] Setting Treatment Parameters:
[0056] Fluence: Set at 1-5 watts for the CoolTouch 1320 nm laser.
[0057] Adjust as needed to achieve effective hemostasis and tissue heating.
[0058] When using higher fluences, the nail bed will reach target temperature more quickly and the speed of hand piece movement will need to be faster.
[0059] Target Temperature: Set at 39° C. (Range is 30° C.-42° C.)
[0060] The system will sound an audible alert, “Beep” when the target nail bed temperature is reached, as well as displaying the temperature on the control panel.
[0061] Each subsequent pass will increase temperature and the target temperature may be reached more quickly than anticipated.
[0062] Cryogen Cooling: Set at 30 msec (Range is 0-50 msec)
[0063] Cryogen will be delivered after the target temperature has been achieved.
[0064] NOTE: These guidelines are meant to establish starting parameters. In any given clinical procedure there are many variables involved, therefore the settings may need to be modified to accomplish the desired treatment goals.
[0065] The CoolBreeze® Mode
[0066] Micro-pulses of laser energy are delivered continuously when the foot pedal is depressed.
[0067] When the target nail bed temperature is reached, system will emit an audible high pitched, rapidly repeating, “beep”. And the firing of the laser will slow.
[0068] Target temperature is displayed continuously on the display panel.
[0069] Movement of the hand piece
[0070] The speed of the hand piece movement and the selected fluence should allow the patient to experience mild to moderate warmth but not a sensation of hot or pain.
[0071] Target temperature and the confirming audible beep will be reached quicker with each additional pass.
[0072] Lightly glide the gold footplate just above the tissue surface, avoiding treatment to the surrounding skin overlap by manipulating the hand piece in a smooth continuous motion.
[0073] Keep the hand piece perpendicular to the nail surface.
[0074] Each pass may be changed to a different orientation of movement for a more uniform distribution of energy.
[0075] Multiple passes will be needed before moving to the next toe.
[0076] Suggested Treatment Interval: Every month for a total of 3-4 treatments
[0077] Treat the nail as it grows out with laser energy and topical anti fungal medications to re stimulate the wound healing response The number of the treatments is based on the condition of the nail and the amount of improvement desired.
[0078] Toenails will re grow in a few months and the improvement should be seen immediately.
[0079] Post Procedure Care:
[0080] Wear comfortable shoes and hosiery that allow your feet some breathing space.
[0081] Wear shoes, sandals or flip-flops in community showers or locker rooms.
[0082] Wash your feet every day, dry them thoroughly and use an antiperspirant. Ask your doctor to recommend an antiperspirant with the right blend of ingredients.
[0083] Wear clean socks or stockings every day.
[0084] Keep toenails trimmed.
[0085] Disinfect pedicure tools before and after you use them. Note: Be sure to wipe the footplate with an appropriate disinfectant when finish treating each patient and before storing the handpiece.
[0086] Experimental Results
[0087] The present invention comprises the step of exposing the infected tissue by removal of the nail plate and irradiating the nail bed with infrared radiation using laser energy having a wavelength between about 800 nm and about 2000 nm, and more particularly, using laser energy having a wavelength of about 1200 to 1600 nm. A preferred wavelength is 1320 nm
[0088] The present invention further comprises the step of exposing the infected tissue by removal of the nail plate and irradiating the nail bed with infrared radiation using laser energy having a wavelength between about 1450 nm and about 1550 nm, and more particularly, using laser energy having a wavelength of about 1470 nm.
[0089] Experiment I:
[0090] The CoolTouch® 1320 nm laser was used to treat infected toes in 50 individuals with a single avulsion treatment and follow up laser treatments every 5 weeks. New clear growth was seen at three months and the nails are completely clear at 6 months post treatment.
[0091] Background:
[0092] Organisms that cause onychomycosis can invade both the nail bed and the nail plate. Dermatophytoses of the fingernails and toenails, in contrast to those at other body sites, are particularly difficult to eradicate with drug treatment. This is the consequence of factors intrinsic to the nail—the hard, protective nail plate, sequestration of pathogens between the nail bed and plate, and slow growth of the nail, as well as of the relatively poor efficacy of the early pharmacologic agents.
[0093] The efficacy of current treatment options, including topical, oral, mechanical and chemical therapies or a combination of these modalities is low. Topical drug treatment for onychomycosis is not usually successful because they are unable to penetrate the nail plate, as disclosed in Crawford, F, Young P, Godfrey C et al., “Oral treatments for toenail onychomycosis: a systematic review,” Arch Dermatol 138, 811-816 (2002) and Elewski, B. E., “A full ‘cure’ for onychomycosis is not always possible,” Arch Dermatol 135, 852-853 (1999), and rapid recurrence can occur after discontinuing use. Oral antifungal agents are more effective although more toxic with a significant risk of liver toxicity, prolonged loss of taste, and life-threatening drug interactions as discussed in Katz, H. I., “Drug interactions of the newer oral antifungal agents,” Br J Dermatol 141(Suppl. 56), 26-32 (1999). Fungal resistance can occur when the oral antifungal agents are used on a long-term basis. Topically applied antifungal drugs may work somewhat better adjunctive to surgical removal or chemical dissolution of the nail plate as disclosed in Grover, C., Bansal S., Nanda S. et al., “Combination of surgical avulsion and topical therapy for single nail onychomycosis: a randomized controlled trial,” Br I Dermatol 157, 364-368 (2007). But the results were still poor and this study concluded that “Surgical nail avulsion followed by topical antifungal therapy cannot be generally recommended for the treatment of onychomycosis.” This current invention adds the critical new step of laser irradiation immediately post operative and improves the results of nail avulsion dramatically.
[0094] Device Description:
[0095] The CoolTouch® CT3P CoolBreeze 1320 nm 18W pulsed Nd:YAG laser is an FDA (K043046) cleared device and is indicated for use in dermatology for incision, excision, ablation and vaporization with hemostasis of soft tissue.
[0096] The unique handpiece design of the CoolTouch® laser allows the operator to maintain a constant distance from the area to be treated resulting in constant and uniform energy delivery. Treatment spot size is adjustable from 3 mm to 10 mm allowing pre-selection of the optimal spot size for the nail being treated. The energy delivered to the toenail can be adjusted by the selecting the desired level of watts (1.5 W to 12 W) with a push of a single control panel key. The CT3P CoolBreeze™ laser has a unique thermal sensing mechanism design to control the amount of energy delivered to the toenail by pre-setting the desired end target temperature. In addition, patient comfort is assured by a spray of a cooling agent when the target temperature is reached. Unlike other laser systems, having the fiber enclosed and terminated in the handpiece means that the fiber does not need cleaving during or after the laser procedure.
[0097] In this early assessment of the CoolTouch® CT3P CoolBreeze 1320 nm laser for the treatment of onychomycosis, no attempt was made to narrow the cohort of patients by selective eliminating those patients with proximal infections and nail matrix involvement, the very difficult to treat patient group usually non-responsive to pharmacologic agents. A two or three laser treatment regimen allows much higher patient compliance with the treatment protocol, very high patient safety with minimal side effects. Documented high patient satisfaction with minimal patient reported pain or discomfort suggests a safe and tolerable procedure. In addition, using the CoolTouch® CT3P CoolBreeze laser the procedure can be performed in less than 15 minutes (total treatment time for both feet and all toes with multiple passes) and allows effective utilization of valuable physician time.
[0098] Improved nail clearing demonstrated with these preliminary results support the hypotheses that the 1320 nm wavelength, using controlled energy delivery and a cooling spray is an effective treatment modality that inhibits or destroys the dermatophyte pathogens that cause onychomycosis resulting in high patient satisfaction.
[0099] Concurrently-owned U.S. Pat. No. 5,820,626 entitled COOLING LASER HANDPIECE WITH REFILLABLE COOLANT RESERVOIR, U.S. Pat. No. 5,976,123 entitled HEAT STABILIZATION, U.S. Pat. No. 6,451,007 entitled THERMAL QUENCHING OF TISSUE, U.S. Pat. No. 7,122,029 entitled THERMAL QUENCHING OF TISSUE, U.S. Pat. No. 6,413,253 entitled SUBSURFACE HEATING OF MATERIAL, are hereby incorporated herein in their entireties in regards to their teaching of methods and apparatus for cryogenic cooling as part of an overall medical, dermatological and/or aesthetic treatment.
EXAMPLE II
Of Treatment Protocol
[0100] CoolBreeze® Treatment Guideline for Laser Assisted Nail Avulsion
[0101] Laser assisted nail avulsion is a new and novel technique that provides the physician with a successful methodology to provide clear nails for the most difficult to treat subset of patients with onychomycosis. The cohort for this treatment is the approximate 20% of patients who do not respond well to the use of simple laser treatment to produce clearing of the nail. This difficult to treat group include those patients with decades long standing disease, all ten nails infected, highly dystrophic, yellowed nails and are usually elderly.
[0102] The CoolBreeze® laser produces 1320 nm laser energy that is specifically heats the tissue of the nail bed and inhibits dermatophyte growth and re-infection of the tissues. In addition, this heating of the nail bed tissue after nail removal coagulates the surface of the nail bed tissues and stimulates a wound healing response.
[0103] CoolBreeze® lasers provide a continuous delivery of energy, controlled by selecting the desired target temperature, that results in heating a larger volume of tissue and penetrating to a deeper depth. This provides an effective treatment just below the pain threshold, heating the nail bed to produce the desired anti-fungal, wound healing and nail rejuvenation effect.
[0104] The following guidelines are meant to establish starting parameters. In any given clinical procedure there are many variables involved, therefore the settings may need to be modified to accomplish the desired treatment goals. As with any medical procedure the final responsibility and treatment choice lies with the practitioner.
[0105] Patient Selection and Preparation:
Nail avulsion is a surgical procedure with a significant associated recovery time. Proper patient selection is critical. These patients should be selected from that group that has responded poorly or not at all to standard laser treatments for onychomycosis. Perform a digital block for anesthesia to toes that are selected for nail avulsion. Rubber banding is recommended to use as a tourniquet to restrict venous flow and provide a bloodless field. Remove nail using a standard surgical technique. It is important to scrap nail bed and remove all debris from nail folds. Provide laser safety eyewear for operator and patient.
[0113] Setting Laser Treatment Parameters: (Post Nail Avulsion):
I. Set spot size to 3 mm II. Set power to 3.0 Watts III. Set cryogen to 10 msec IV. Set target temperature to 38° C.
[0118] 1. Starting at 3 Watts, treat the avulsed area using a continuous motion and multiple passes until the entire nail bed is at target temperature (this may take 10 or more cryogen sprays.) The nail bed should appear coagulated, semi-dry with minimal exudate. It is very important to treat matrix and lateral/medial folds.
[0119] 2. Increase power to 3.5 Watts and treat a second time.
[0120] 3. The third and final pass is at 4.0 Watts for all avulsed nail beds.
[0121] Note: These guidelines are meant to establish starting parameters. In any given clinical procedure there are many variables involved, therefore the settings may need to be modified to accomplish the desired treatment goals. As with any medical procedure the treatment choice and final responsibility lies with the practitioner.
[0122] Treatment Technique Hints:
[0123] Note: Before each procedure inspect handpiece lens for contamination and clean the lens if necessary. Refer to Operation Manual for detailed instructions.
[0124] The CoolBreeze® Mode:
Micro-pulses of laser energy are delivered continuously when the foot pedal is depressed. When the target nail bed temperature is reached, system will emit an audible high pitched, rapidly repeating, “beep”. The firing of the laser will slow and cryogen will be sprayed on to the nail plate. Target temperature is displayed continuously on the display panel. The red aiming beam spot indicates the approximate size of the treatment area. However, the mid-infrared treatment beam overlaps the red spot and is invisible to the naked eye.
[0129] Movement of the Hand Piece:
Target temperature and the confirming audible beep will be reached quicker with each additional pass and over areas of the avulsed nail.. Lightly glide the gold footplate across the nail surface, avoiding treatment to the proximal and lateral folds Move the hand piece in a smooth and continuous motion. To maintain an accurate temperature reading, do not stop movement of the handpiece during the laser treatment. Keep the hand piece spacer tip contacting the nail and perpendicular to the nail surface. Each pass may be changed to a different orientation of movement for a more uniform distribution of energy. Multiple passes (reaching target temperature with cryogen cooling spray each time) will be needed before treating the next toe.
[0137] Treatment Interval:
Reschedule patient for a 2nd treatment four (4) weeks from initial treatment date. Treat with laser as outlined above. Since toenails grow very slowly, improvement is not seen immediately. Changes in the nail bed are cellular in nature and take time Improvement may be seen over a period of several months as the undamaged nail grows out.
[0140] Post Procedure Care:
Post avulsion—use gauze 4×4's and then wrap with appropriate elastic bandaging materials. Post-op regimen: topical antibiotic—Neosporin b.i.d. (30 days), anti-perspirant starting immediately post op. Dry avulsed nail beds, re-bandage after application of Neosporin. Wear comfortable shoes and hosiery that allow your feet adequate breathing space. Wear shoes, sandals or flip-flops in community showers or locker rooms. Wear clean socks or stockings every day.
[0147] Note: Be sure to wipe the gold treatment tip with an appropriate disinfectant after treating each patient and before storing the hand piece.
[0148] FIG. 4 is a representative illustration of laser assisted wound healing. As shown in FIG. 4 , CoolBreeze® 1320 laser assisted wound healing of R. G. Geronemus et al., clinical study in 2011.
[0149] FIG. 5 is a representative illustration of laser assisted nail avulsion. As shown in FIG. 5 , CoolBreeze® 1320 laser assisted nail avulsion in R. Nordyke clinical study in January 2011.
[0150] Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the present invention belongs. Although any methods and materials similar or equivalent to those described can be used in the practice or testing of the present invention, the preferred methods and materials are now described. All publications and patent documents referenced in the present invention are incorporated herein by reference.
[0151] While the principles of the invention have been made clear in illustrative embodiments, there will be immediately obvious to those skilled in the art many modifications of structure, arrangement, proportions, the elements, materials, and components used in the practice of the invention, and otherwise, which are particularly adapted to specific environments and operative requirements without departing from those principles. The appended claims are intended to cover and embrace any and all such modifications, with the limits only of the true purview, spirit and scope of the invention. | A method of treating inaccessible microbial infections, the method comprising the steps of exposing the microbe, irradiating the microbe with infrared radiation and cooling such that heat inactivates the pathogen and stimulates a wound healing response in the patient. | 0 |
TECHNICAL FIELD
The present invention relates to a turbocharger for use in an internal combustion engine, and, more particularly, to a turbocharger including a multi-stage turbine.
BACKGROUND
An internal combustion engine may include one or more turbochargers for compressing a fluid which is supplied to one or more combustion chambers within corresponding combustion cylinders. Each turbocharger typically includes a turbine driven by exhaust gases of the engine and a compressor which is driven by the turbine. The compressor receives the fluid to be compressed and supplies the fluid to the combustion chambers. The fluid which is compressed by the compressor may be in the form of combustion air or a fuel/air mixture.
U.S. Pat. No. 3,044.683 (Woollenweber) discloses a fluid passage extending from the high pressure side of the compressor to the inlet side of a turbine. A spring loaded valve is disposed within the fluid passage and opens upon a high pressure condition within the compressor. The spring loaded valve thus merely acts to bypass some of the high pressure gas on an over pressure condition to the turbine of the turbocharger.
U.S. Pat. No. 5,724,813 (Fenelon et al.) assigned to the assignee of the present invention, discloses a turbocharger having a single stage compressor. A portion of the compressed gas from the single stage compressor may be recirculated to the outlet side of the turbine using controllably actuated valves. The control scheme utilizes only a single stage compressor.
U.S. Pat. No. 5,701,741 (Halsall) discloses a turbocharger having a single stage turbine driven by exhaust gas from an exhaust manifold. A bypass valve is fluidly connected at opposite ends with the inlet and outlet to the turbine. The valve may be actuated to bypass exhaust gas around the turbine. The rotational speed of the single stage compressor may thereby be adjusted.
Bypass systems as described above which bypass from the compressor to the turbine are primarily used to prevent a “surge” condition within the compressor, rather than adjust power inputs to the compressor. Bypass systems which bypass the entire turbine are used to control the power input to the compressor. Since the entire turbine is bypassed, however, the ability to control the power input to the compressor and thus the boost from the compressor is limited. That is, it may not be possible to selectively control the boost from the compressor over a relatively wide operating range.
The present invention is directed to overcoming one or more of the problems as set forth above.
SUMMARY OF THE INVENTION
In one aspect of the invention, a turbocharger for an internal combustion engine is provided with a two stage turbine including a first turbine stage and a second turbine stage. A wastegate conduit is fluidly coupled with the two stage turbine. The wastegate conduit bypasses only a single one of the first turbine stage or second turbine stage. A valve is positioned in association with the wastegate conduit for controlling flow through the wastegate conduit. A compressor is coupled with and rotatably driven by the two stage turbine.
In another aspect of the invention, a method of operating a turbocharger in an internal combustion engine is provided with the steps of: providing a two stage turbine including a first turbine stage and a second turbine stage; fluidly coupling a wastegate conduit with the two stage turbine so as to bypass only a single one of the first turbine stage and the second turbine stage; providing a compressor mechanically coupled with the two stage turbine; controlling a flow of exhaust gas through the wastegate conduit; and rotatably driving the compressor with the two stage turbine.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view of an embodiment of a turbocharger of the present invention for use with an internal combustion engine.
DETAILED DESCRIPTION
Referring now to the drawing, there is shown an embodiment of a turbocharger 10 for use with an internal combustion engine 12 .
Internal combustion engine 12 generally includes a plurality of combustion cylinders 14 , only three of which are shown for simplicity sake in the drawing. The particular number of combustion cylinders 14 within internal combustion engine 12 may vary, depending upon the particular application. Internal combustion engine 12 also includes an exhaust manifold 16 and an inlet manifold 18 . Inlet manifold 18 provides air or a fuel/air mixture to combustion cylinders 14 . Exhaust manifold 16 receives exhaust gas from combustion cylinders 14 . Exhaust manifold 16 and inlet manifold 18 are shown with a single part construction for simplicity sake in the drawing. However, it is to be understood that exhaust manifold 16 and/or inlet manifold 18 may be constructed as multiple-part manifolds, depending upon the particular application.
Turbocharger 10 includes a two stage turbine 20 and a two stage compressor 22 . Two stage turbine 20 is fluidly coupled with exhaust manifold 16 as indicated schematically by line 24 . Two stage turbine 20 includes a first stage in the form of a radial or mixed flow turbine wheel 26 and second stage in the form of an axial turbine 28 . Turbine wheel 26 and axial turbine 28 are each carried by a shaft 30 and rotatable about a longitudinal axis 32 of shaft 30 . More particularly, two stage turbine 20 includes a volute section 34 which receives exhaust gas from exhaust manifold 16 via line 24 . Volute section 34 may be in the form of a single volute as shown, or may be in the form of a split volute or other configuration, depending upon the particular application. Exhaust gas enters volute section 34 and impinges against a plurality of vanes 36 of turbine wheel 26 . Turbine wheel 26 is thus rotatably driven by exhaust gas from exhaust manifold 16 .
The exhaust gas flows in an axial direction away from turbine wheel 26 and impinges against a plurality of vanes 42 disposed radially around shaft 30 and between turbine wheel 26 and axial turbine 28 . Vanes 42 are controllably actuated, as indicated by double headed arrow 44 to adjust air flow rate and direction downstream from turbine wheel 26 .
The exhaust gas then flows to and impinges against a plurality of blades 46 of axial turbine 28 positioned radially around shaft 30 . The particular configuration and pitch angle of blades 46 may of course be dependent upon the particular application. The spent exhaust gas then flows to a muffler system (not shown) positioned downstream from turbocharger 10 , as indicated by directional arrow 48 .
Two stage compressor 22 includes a first compressor 50 and a second compressor 52 . First compressor 50 and second compressor 52 each include a compressor wheel 54 and 56 , respectively. Two stage compressor 22 receives combustion air as indicated by directional arrow 58 . First compressor wheel 54 and second compressor wheel 56 compress the combustion air in a series manner to provide a desired total compression ratio. Second compressor wheel 56 discharges the compressed combustion air into a volute section 60 which is fluidly coupled with inlet manifold 18 as indicated schematically by line 62 . Two stage compressor 22 thus provides compressed combustion air to inlet manifold 18 .
According to an aspect of the present invention, wastegate conduits 64 and 66 are fluidly coupled with two stage turbine 20 . Wastegate conduits 64 and 66 respectively bypass only a single one of first turbine stage (i.e., turbine wheel) 26 or second turbine stage (i.e., fan) 38 . In the embodiment shown, wastegate conduit 64 bypasses first turbine stage 26 , and wastegate conduit 66 bypasses second turbine stage 28 .
More particularly, first turbine stage 26 includes an inlet and an outlet which are respectively positioned upstream and downstream therefrom. Similarly, second turbine stage 28 includes an inlet and an outlet which are respectively positioned upstream and downstream therefrom. Wastegate conduit 64 has an inlet end fluidly coupled with the inlet of first turbine stage 26 and an outlet end fluidly coupled with the outlet of first turbine stage 26 . Wastegate conduit 66 has an inlet end fluidly coupled with the inlet of second turbine stage 28 and an outlet end fluidly coupled with the outlet of second turbine stage 28 . In the embodiment shown, the outlet end of wastegate conduit 64 and inlet end of wastegate conduit 66 are each fluidly coupled with a region between first turbine stage 26 and nozzle vanes 42 . However, it will also be appreciated that the outlet end of wastegate conduit 64 and/or the inlet end of wastegate conduit 66 may be fluidly coupled with the region between diverter vanes 42 and second turbine stage 28 .
Each wastegate conduit 64 and 66 includes a controllably actuatable valve 68 associated therewith. Valves 66 and 68 may be of conventional design, and may be configured to fully open or close, or be adjusted to an intermediate position between the full opened and closed positions.
Controller 70 is electrically coupled with each valve 68 via lines 72 and 74 , respectively. Controller 70 is also electrically coupled with one or more sensors 76 via an associated line 78 and receives an input signal therefrom. Sensor 76 senses an operating parameter associated with operation of turbocharger 10 and/or internal combustion engine 12 used to controllably actuate valves 66 and 68 .
INDUSTRIAL APPLICABILITY
During use, internal combustion engine 12 operates in known manner using, e.g., the diesel principle of operation. Exhaust gas is transported from exhaust manifold 16 to volute section 34 of two stage turbine 20 via line 24 . The exhaust gas impinges upon vanes 36 of turbine wheel 26 and rotatably drives turbine wheel 26 . The exhaust gas flows downstream from turbine wheel 26 to diverter vanes 42 . Vanes 42 may be controllably actuated, such as using controller 70 , to control the flow rate and/or flow direction of the exhaust gas. The exhaust gas then flows to second turbine stage or axial turbine 28 . The exhaust gas impinges against blades 46 of axial turbine 28 to assist in the rotational driving of two stage turbine 20 . The spent exhaust gas is then discharged to a muffler system, as indicated by arrow 48 .
Rotation of turbine wheel 26 and axial turbine 28 in turn causes rotation of shaft 30 which drives first compressor wheel 54 and second compressor wheel 56 of two stage compressor 22 . Combustion air or a fuel/air mixture is drawn into first compressor 50 , as indicated by arrow 58 . The combustion air or fuel/air mixture is compressed in a series manner within two stage compressor 22 using first compressor wheel 54 and second compressor wheel 56 . The compressed combustion air or fuel/air mixture is discharged from volute section 60 of second compressor 52 to inlet manifold 18 via line 62 .
Sensor 76 senses one or more operating parameters associated with internal combustion engine 12 and/or turbocharger 10 used to adjust the output power and/or rotational speed of shaft 30 within two stage turbine 20 . For example, it may be desirable to control the power level or boost of two stage compressor 22 . The boost of two stage compressor 22 is primarily dependent upon the rotational speed of shaft 30 . Under certain operating conditions, more or less boost from two stage compressor 22 may be desirable. By controlling valves 68 associated with wastegates conduit 64 and 66 , the boost of two stage compressor 22 can in turn be controlled. Controller 70 controllably actuates a selected valve 68 to open wastegate conduit 64 or 66 , or both simultaneously.
In a preferred method of operation, the plurality of nozzle vanes 42 disposed radially around shaft 30 are controllably positioned to control the air flow rate and/or air flow direction between turbine wheel 26 and axial turbine 28 . By controllably positioning vanes 42 , the boost of two stage compressor 22 can be controlled to some extent. However, it is not always possible to control the boost of two stage compressor 22 , depending upon the particular operating conditions of internal combustion engine 12 . Under such circumstances, nozzle vanes 42 are first adjusted and thereafter valves 68 are controllably actuated to open wastegate conduit 64 and/or 66 .
In contrast with conventional wastegate designs which bypass an entire two stage turbine from the inlet of the first turbine stage to the outlet of the second turbine stage, wastegate conduits 64 and 66 bypass only a single turbine stage within two stage compressor 20 . It is therefore possible to more precisely control the boost of two stage compressor 22 since only a portion of two stage turbine 20 is bypassed. For example, the pressure ratio at the inlet and outlet of turbine wheel 26 likely is different than the pressure ratio at the inlet and outlet of axial turbine 28 . By utilizing the known pressure ratios of turbine wheel 26 and/or axial turbine 28 , the rotational speed of shaft 30 may be more closely controlled. This in turn results in improved control of the boost from two stage compressor 22 .
Other aspects, objects and advantages of this invention can be obtained from a study of the drawings, the disclosure and the appended claims. | A turbocharger for an internal combustion engine, particularly suitable for use in a work machine, is provided with a two stage turbine including a first turbine stage and a second turbine stage. A wastegate conduit is fluidly coupled with the two stage turbine. The wastegate conduit bypasses only a single one of the first turbine stage or second turbine stage. A valve is positioned in association with the wastegate conduit for controlling flow through the wastegate conduit. A compressor is coupled with and rotatably driven by the two stage turbine. The controllable wastegate conduit provides effective control of the power input to the compressor. | 5 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates generally to a system for analyzing lumber and determining a preferred path for cutting the lumber. More particularly, the present invention relates to a system for cutting blanks from a piece of lumber where the lumber is analyzed and the blanks to be cut from the lumber are arranged to maximize the value of the cut parts from the lumber and minimize waste.
[0003] 2. Discussion of the Prior Art
[0004] Throughout history, the woodworking industry has continually strived to reduce the amount of waste in order to maximize profits and for environmental concerns, such as excessive deforestation and disposal of scrap lumber. Maximizing the utilization of lumber has met with numerous challenges in an increasingly industrialized world. For example, each piece of lumber is unique having its own shape, density, color, and defects. In the more industrialized sectors of the woodworking industry where mass production is required, many thousands of identical pieces or blanks are needed to be cut from these uniquely individual pieces of lumber. As a result, the placement of the blanks to be cut from each piece of lumber is time consuming and often results in great waste.
[0005] Several systems have been developed in order to maximize the utilization of lumber and minimize waste. For example, U.S. Pat. No. 4,221,974 to Mueller et al. (the Mueller patent) discloses a system for inspecting lumber and optimizing the utilization of the lumber. U.S. Pat. No. 3,120,861 to Finlay et al. (the Finlay patent) discloses a system that incorporates an electro-optical device for scanning a piece of lumber for flaws. U.S. Pat. No. 3,329,181 to Buss et al. (the Buss patent) discloses another electro-optical device for scanning a piece of lumber and for providing input to software used in nesting or optimization. While each of these references represent some form of an advance in the state of the art of mass-production wood cutting and processing, they still result in relatively high percentages of waste, and thus lower the value of the cut parts than could be otherwise obtained.
BRIEF SUMMARY OF THE INVENTION
[0006] A lumber processing system constructed in accordance with the present invention accepts incoming marked lumber and produces cut parts of any of various, desired, predetermined shapes. The system broadly includes a scanning section, a computer section and a cutting section. Incoming lumber is scanned in the scanning section using two color cameras capturing images of both sides of the lumber first under normal lighting and second under ultraviolet (black) lighting for illumination of pre-marked defects. Images are processed in the computer section to produce a polygonal model of each section. These section models are then merged to produce a complete polygonal model of the entire scanned piece of lumber. A series of auxiliary packing computers review the complete model and each determine separate solutions for cutting the lumber to create the predetermined shapes. Parts are then ‘punched’ from the lumber in the cutting section utilizing high power lasers cutting from both sides of the lumber simultaneously. It should be noted that these parts, or blanks, are later worked to create a finished product, such as a gun stock.
[0007] The system includes a plurality of computers performing three classes of functions. A first class includes a main computer that provides a user interface for controlling the system and for inputting data representative of the desired shapes that will be cut from the lumber. A second class includes a machine control computer that provides control of the cutting section. A third class has a plurality of packing computers that calculate potential packing solutions during the available time between scanning and cutting of the lumber, or as defined by the user.
[0008] The main computer performs several functions. The main computer coordinates overall system operation, provides the user interface, receives continuous system status updates and updates the user interface as appropriate, creates logs of system operation, generates a desired cutting path based on polygonal packing solutions, transmits the desired cutting path to Machine Control computer, and receives video images from the scanning system to create a complete polygonal model of the piece of lumber being cut.
[0009] The machine control computer continuously scans for inputs and generates appropriate outputs, provides manual control of the cutting section while in a manual mode, coordinates the cutting section operation when in automatic mode, reports cutting section status to the main computer, and receives the desired cutting path from main computer. In addition, the machine control computer provides manual and automatic control of the scanning section.
[0010] The auxiliary packing computers each receive a unique algorithm from the main computer. The packing computers also receive a cutting bill and the polygonal model of the lumber from the main computer. Each of the packing computers then independently and repeatedly generate packing solutions based on the cutting bill and the polygonal model, retaining the highest scoring solution in accordance with their unique system parameters. Once a predetermined time has elapsed, the lumber is moved to the cutting section and into position for cutting and then each packing computer transmits its highest scoring solution to the main computer.
[0011] Once the main computer receives the packing computer solutions, the main computer selects the highest scoring solution from the packing computer solutions as the cutting solution. The associated cutting path is then transmitted to the machine control computer. Once the cutting path is received by the machine control computer and the piece of lumber is in position for cutting, the cutting section will cut the lumber in accordance with the cutting path.
[0012] The lumber is cut using high powered lasers positioned on each side of the lumber. The lasers cut the lumber simultaneously and are powered so that the lumber is cut completely through from side to side without damaging each other. The laser cuts are relatively precise so that the blanks cut by the lasers do not fall from the piece of lumber, but are easily removed once the cut lumber is moved out of the system.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0013] A preferred embodiment of a lumber processing system is described in detail below with reference to the drawing figures, wherein:
[0014] FIG. 1 is a schematic drawing of a lumber processing system constructed in accordance with a preferred embodiment of the present invention;
[0015] FIG. 2 is a block diagram of the computer section of the system;
[0016] FIG. 3 is a flow chart diagram of the main computer ALPSX program;
[0017] FIG. 4 is a flow chart diagram of the hardware initialization;
[0018] FIG. 5 is a flow chart diagram of the LOG message processing;
[0019] FIG. 6 is a flow chart diagram of inter-computer communications within the computer section;
[0020] FIG. 7 is a flow chart diagram of the overview of the image acquisition and processing thread of the system;
[0021] FIG. 8 is a flow chart diagram of the image acquisition of lumber in the scanning section;
[0022] FIG. 9 is a flow chart diagram of the processing of scanning data collected by the scanning section;
[0023] FIG. 10 is a flow chart diagram of the overview of the packing solution process performed by the computer section of the system;
[0024] FIG. 11 is a flow chart diagram of the packing solution process of the system;
[0025] FIG. 12 is a flow chart diagram of the cutting path solution process;
[0026] FIG. 13 is a flow chart diagram of the initialization process of the system;
[0027] FIG. 14 is a flow chart diagram of the hardware initialization process of the system;
[0028] FIG. 15 is a flow chart diagram of the system sequencing thread;
[0029] FIG. 16 is a flow chart diagram of the system control loop;
[0030] FIG. 17 is a flow chart diagram of the auxiliary packing computer initialization;
[0031] FIG. 18 is a flow chart diagram of the packing thread;
[0032] FIG. 19 is a flow chart diagram of the cutting solution selection performed by the main computer; and
[0033] FIG. 20 is a flow chart diagram of the operation of the lumber processing system.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0034] Referring now to the drawings, FIG. 1 depicts a preferred embodiment of a lumber processing system 10 . The system 10 broadly includes a scanning section 12 , a computer section 14 , and a cutting and output section 16 . Generally, the pieces of lumber configured for use in the system 10 are elongated and present a pair of opposed faces with a rectangular cross-sectional shape. For example, the piece of may have a 2″×10″ cross-sectional dimension. Of course, the system 10 may also accommodate lumber of various other dimensions.
[0035] The scanning section 12 includes an infeed conveyor 18 for receiving a piece of lumber. The infeed conveyor 18 transfers the lumber to a rotation station 20 along a central conveyor 22 . The rotation station 20 uses a plurality of swing bars 24 to rotate the lumber from a flat, horizontal configuration to a vertical configuration where the faces of the lumber are generally vertical. A plurality of clamping pins 26 is provided to firmly support the lumber in the vertical configuration. Each of the pins 26 contacts a side of the lumber once the swing bars 24 rotate the lumber to the vertical position, clamping the lumber to the central conveyor 22 .
[0036] A camera array carriage 28 includes a pair of opposed cameras 30 for taking images of the faces of the lumber under white light and ultraviolet, or black, light. Once the lumber has been positioned vertically on the central conveyor 22 , the carriage 28 moves along the lumber in a first direction wherein the cameras 30 take images of the lumber alternating between white and black light, and then the carriage reverses course and moves along the lumber in a second direction until the carriage 28 has returned to its start position. The images are transferred to the computer section 14 for analysis.
[0037] Turning now to FIG. 2 , the computer section 14 includes a plurality of computers coupled in a network performing three basic functions. All of the computers 32 , 34 , 36 , 38 , 40 , 42 are linked via a standard TCP/IP interface enabling physical placement of computers 32 , 34 , 36 , 38 , 40 , 42 at remote connected locations as desired. In addition, the standard network interface among the computers allows for remote connectivity to the system 10 for debugging and monitoring.
[0038] A first class includes a main computer 32 having a CRT and keyboard as a user interface for operating the system 10 . A second class includes a machine control computer 34 that provides control of the cutting section 12 . A third class includes four packing computers 36 , 38 , 40 , 42 that calculate potential packing solutions during the available time between scanning and cutting of the lumber. The computers 32 , 34 , 36 , 38 , 40 , 42 of the computer section 14 are operably coupled with the scanning and cutting sections 12 , 16 of the system 10 to enable command and control over the system 10 .
[0039] The main computer 32 receives the images of the lumber generated by the cameras 30 and assembles a complete polygonal model of the lumber for analysis by the packing computers 36 , 38 , 40 , 42 . Each of the packing computers 36 , 38 , 40 , 42 then run a selected packing algorithm in order to create a cutting solution for the lumber. The selected algorithms are assigned to each of the packing computers 36 , 38 , 40 , 42 by the main computer and are designed to create one or more cutting solutions for the lumber based upon the various criteria including simplicity, minimized waste and maximized value.
[0040] Once the packing computers 36 , 38 , 40 , 42 transfer the possible cutting solutions to the main computer 32 , the main computer 32 selects the final cutting solution to be used by the system 10 . Once packed, the main computer 32 calculates a cutting path for the board which minimizes the length of travel of laser assemblies 44 required to cut all parts from the board. The main computer 32 passes the cutting path calculated from the final cutting solution to the control computer 34 , which in turn causes the cutting section 16 to carry out the solution by cutting the lumber in accordance with the solution.
[0041] The cutting section 16 includes a pair of opposed laser assemblies 44 mounted on either side of a laser carriage 46 . The laser assemblies 44 each include a laser head 48 and are configured to direct a beam of collimated light of a predetermined energy on a target. The energy level of the laser may be adjusted to accommodate lumber of various thicknesses and densities, and the cutting speed. In addition, the laser beams are of such an energy level that they cut through only one half of the thickness of the lumber. The benefits of providing opposed laser assemblies 44 of variable energy are twofold. First, the beams, which are opposed, will not impinge upon each other, a situation that would damage the laser assemblies 44 . Second, by providing two opposed laser assemblies 44 , the blanks are cut from the lumber relatively quicker than if the system 10 utilized one laser assembly.
[0042] The overall operation of the system 10 is controlled by the ALPSX™ program. Prior to use of the system 10 , the system is initialized as shown in FIGS. 3, 4 , 5 and 6 . In operation, an operator places a working piece of lumber on the infeed conveyor 18 and inspects the lumber one face at a time. Defects such as knots, pits or other undesirable portions are marked using a florescent marking crayon common in the wood working industry.
[0043] After each side is inspected and marked, the lumber is fed in a horizontal configuration using the infeed conveyor 18 into the system 10 until the lumber is positioned on the central conveyor 22 at the rotation station 20 . The swing bars 24 rotate the lumber into the vertical configuration, locking pins 26 clamp the lumber in this configuration, and the swing bars 24 are retracted.
[0044] Referring now to FIG. 7 , a series of images of each face of the lumber is captured by the cameras 30 . A source of white light mounted and a source of black light are within the camera carriage 28 for illuminating the faces of the lumber along a section thereof. As the carriage 28 makes a first pass over the lumber in a first direction, the carriage will stop at a section of the lumber, the white light source will illuminate the faces of the lumber along the section and the cameras 30 will capture white light images of the lumber, and then the white light source will extinguish, the black light source will be activated to illuminate the faces of the lumber, and the cameras 30 will capture a black light image of the section of the lumber. This process is detailed in FIG. 8 and is repeated until the entire piece of lumber is scanned. The images are used by the main computer 32 to create a single, polygonal model of the lumber for processing by the packing computers 36 , 38 , 40 , 42 . The polygonal model of the lumber indicates defects in the lumber such as knots and pitting, and shows areas on the lumber that are less desirable for cutting blanks. The model is displayed on the CRT of the main computer 32 . The creation of the polygonal model is shown in FIG. 9 .
[0045] Once the camera carriage 28 has returned to its start position, the lumber is transferred by the central conveyor 22 from the scanning section 12 to the cutting section 16 . After completion and assembly of the images and the creation of the polygonal model, the packing computers 36 , 38 , 40 , 42 solve packing solutions based upon various packing algorithms. . The main computer 32 reviews the white light image and scans for the edges of the lumber and defects in the lumber based generally upon the relative grayness of the lumber as compared with a standard for the particular type of wood being used. Pits and other defects generally show up as more gray or dark and are thus detected under white light. In addition to using white light, the black light images are used to depict defects noted manually by the operator and outlined with the florescent crayon. This information is combined to create the polygonal model.
[0046] An overview of the packing and selection of the preferred cutting path is depicted in FIG. 10 . As illustrated in FIG. 11 , the polygonal model is sent to each of the packing computers 36 , 38 , 40 , 42 . In addition, the cutting bill (detailing the blanks that are to be cut from the board) is sent to the packing computers 36 , 38 , 40 , 42 . Each packing computer 36 , 38 , 40 , 42 then solves for one or more packing solutions based upon the specific algorithm under which it is working. The initialization of the packing computers 36 , 38 , 40 , 42 is shown in FIG. 17 , while the packing thread and packing overview are depicted in FIGS. 18 and 19 , respectively
[0047] The algorithms that are used by the packing computers are designated under the POLYPACK™ name. The first algorithm is designated POLYPACK3™ and is used by packing computer 36 . This algorithm is designed to pack relatively quickly producing minimal complexity solutions rapidly. This algorithm is suitable even for large, complicated pieces of lumber. POLYPACK3™ tends to produce simple solutions with a single part and minimal orientation and rotation changes to parts. This algorithm operates quickly enough to test multiple packing scenarios even for the relatively complicated boards.
[0048] The next algorithm is known as POLYPACK4™ and is assigned to computer 38 . This algorithm is similar to POLYPACK3™ except that it compacts parts or blanks more thoroughly after placement of each blank.
[0049] Packing computer 40 is assigned POLYPACK5™. This algorithm is designed to pack more slowly. It also more closely determines the impact of packing combinations of pieces from the cutting bill. POLYPACK5™ places as many blanks as possible before continuing to the next order in the cutting bill. This algorithm also tends to reorient pieces (horizontal and vertical mirroring) as packing to test potential nesting solutions.
[0050] The final algorithm, POLYPACK6™, is operated by packing computer 42 . This algorithm is designed to pack more exhaustively than the other algorithms and may not produce a solution within production time constraints for larger or more complex boards. This algorithm resolves cutting bill priorities continually while packing to select the highest priority pieces. It also packs pieces to test nesting potential by continually mirroring pieces in both horizontal and vertical directions.
[0051] Once a predetermined time has elapsed, the lumber is moved and placed in the cutting section 16 . The packing process is then closed and the solutions are sent to the main computer 32 . The time is selected by the operator and is generally the amount of time between the end of the imaging process and the travel time required for placement of the lumber in the cutting section 16 , and powering of the laser assemblies 44 for use. The main computer 32 assigns a value to each of the solutions derived by the packing computers 36 , 38 , 40 , 42 and selects the solution with the highest value based upon the relative quality of the blanks, the number of the blanks and the amount of waste. The planning of the cutting path selected for the lumber is shown in FIG. 12 .
[0052] Once the cutting path has been selected by the main computer 32 , the control computer 34 begins initialization of the cutting process. This initialization is depicted in FIGS. 13 and 14 and includes the steps of initializing the control computer hardware and the lasers 44 . The machine sequencing thread and machine control loop are shown in FIGS. 15 and 16 , respectively.
[0053] After the lumber has been cut by the lasers 44 , the lumber is moved by the central conveyor 22 to an outfeed section 50 . The operator then removes the cut lumber from the system and selectively knocks the blanks from the lumber with a soft mallet. It will be appreciated that the blanks may be removed at the site of the system 10 or be transported to a different location for removal. By using two lasers 44 that operate simultaneously providing a relatively precise and aligned, thin cuts, the blanks are retained in the lumber until selective removal. As a result, the cutting of the blanks may take place remotely from the blank removal process and the finishing process used to create a product from the blanks, such as gun stocks. FIG. 20 provides an overview of the operation of the system 10 .
[0054] The present invention has been described with reference to the preferred embodiment of the lumber processing system 10 . It is understood that changes may be made and equivalents employed without departing from the scope of the claims below. | A lumber processing system for cutting lumber into predetermined shapes broadly includes a scanning section, a computer section and a cutting section. Incoming lumber is scanned in the scanning section using two-color cameras capturing images first under normal lighting and second under ultraviolet (black) lighting for illumination of pre-marked defects. Images are processed in the computer section to produce a polygonal model of the lumber. A series of auxiliary packing computers review the model and determine separate solutions for cutting the lumber. Parts are then ‘punched’from the lumber in the cutting section utilizing high power lasers cutting from both sides of the lumber simultaneously. | 1 |
FIELD OF THE INVENTION
The present invention relates to an adjustable buoyancy floating fish lure having remote and manual buoyancy adjustments to vary the buoyancy of the fish lure, thereby controlling the water depth the fish lure will attain. The fish lure of the present invention comprises a fore and aft chamber held together by an attaching means and the buoyancy of the fish lure is adjusted by the relative rotation between the fore and aft chambers. The present invention is not limited to a fishing lure, but can also be used to control and maintain the depth of live bait and other lures.
BACKGROUND OF THE INVENTION
Fishing floatation devices have been used for centuries, utilizing cork objects and wood attached to fishing line to serve as bobbers. Such types of bobbers reside on the water surface and are desirable for preventing the hook from becoming caught or snared on the bottom of the body of water. Although conventional bobbers prevent the hooks from catching on rocks or trees located under the surface of the water, their cumbersome size and color is often undesirable to fish. Additionally, since bait typically extends directly beneath the bobber, the hook setting capability is extremely undesirable, in that when a fisherman sets the hook by lifting his/her rod, the bobber moves first before the hook is set. This premature movement of the bobber prior to setting the hook can scare fish away from the hook.
Additionally, fishing sinkers have also been used for many years and are advantageous for casting long distances and preventing the current of moving water from displacing fishing bait from a desired location. Although fishing sinkers have some desirable features, sinkers typically pull the fishing bait or lure to the bottom of the body of water, often causing either or both the sinker and hook to snare or catch against rocks, submerged vegetation, or other various obstacles, which is undesirable.
Other conventional fishing devices have a predetermined buoyancy, but are typically undesirable to fisherman, since the fisherman must keep a large number of these devices in the tackle box due to uncertainty of the needed buoyancy. Also conventional fishing devices for controlling the depth and floatation of live bait or lures have been developed to have buoyancy adjustments to control the depth of the bait or lure in the water, but are often cumbersome, require a large number of complex and cumbersome components, are expensive to manufacture, and their respective appearances repel fish.
Thus, there is a need to provide a fishing device which prevents the hook of the bait or lure from catching on rocks or submerged vegetation on the bottom of bodies of water, is of a discrete size, has a desirable natural appearance for fish, is multi-functional in that it can float on top of the water, sink to the bottom and achieve any depth between the bottom and surface of the body of water, with an easily adjustable buoyancy which can be adjusted remotely, is inexpensive to manufacture, and attracts fish.
SUMMARY OF THE INVENTION
The present invention is directed to a fish lure having buoyancy adjustments and comprising fore and aft chambers connected to one another by an attaching means within the body of the fish lure. The fore and aft chambers are rotatable about a central axis and the attaching means is disposed on that central axis through the body of the fish lure. The relative rotation of the fore and aft chambers will vary the buoyancy of the fish lure. The fore chamber includes a first set of a plurality of buoyancy windows and the aft chamber includes a second set of a plurality of buoyancy windows, such that the first and second set of buoyancy windows are relatively adjustable with respect to one another to create a set of a plurality of valve apertures controlling the air to water ratio within the body of the fish lure.
Additionally, the fish lure of the present invention has buoyancy adjustments comprising fore and aft chambers connected to one another by an attaching means, wherein the fore and aft chambers as well as the attaching means are coaxial with each other about a central axis and a first set of a plurality of buoyancy windows are disposed on and around the circumference of a first end of the aft chamber and a second set of a plurality of buoyancy windows are disposed on and around the circumference of a second end of the fore chamber, wherein the first and second set of buoyancy windows are relatively adjustable to one another to create a set of a plurality of valve apertures controlling the air to water ratio within the fish lure. Additionally, the fore chamber comprises a first annular serrated locking means having a first set of a plurality of angled teeth and the aft chamber comprises a second annular serrated locking means having a second set of a plurality of angled teeth, wherein the first and second sets of annular teeth engage each other to lock the fore and aft chambers in a preferred respective position.
In the preferred embodiment of the present invention the attaching means connecting and holding together the fore and aft chambers is a hollow elastic tube having first and second ends, wherein the fore and aft chambers are held together by rotating the elastic tube about the central axis. Since the hollow elastic tube is disposed on and extends along the central axis, a fishing line continuously extends through the hollow elastic tube on and along the central axis through the body of the fish lure. Both the fore and aft chambers of the fish lure are made of a transparent and colorless plastic.
In a second embodiment of the present invention the attaching means includes a threaded end cap and a hollow rod having first and second ends, the first end has a threaded protrusion and the second end includes an annular flange unit and threaded end cap which rotatably engages the threaded protrusion to connect the fore and aft chambers together. To attract nearby fish, an illumination means can be inserted into the hollow rod. Similar to the fish lure of the preferred embodiment of the present invention, the fore and aft chambers are made of transparent and colorless plastic as well as the threaded end cap and hollow rod to produce a covert natural appearance to fish.
BRIEF DESCRIPTION OF THE DRAWINGS
For the purposes of illustrating the invention, there is shown in the drawings, forms that are presently preferred, it being understood, however, that the invention is not limited to the precise arrangements and instrumentalities shown.
FIG. 1 is a perspective view of the adjustable buoyancy floating fish lure of the present invention.
FIG. 2 is an exploded side view of the adjustable buoyancy floating fish lure of the present invention.
FIG. 3 is a side view of the adjustable buoyancy floating fish lure of the present invention prior to engagement with the fishing line and with the buoyancy windows fully open.
FIG. 4 is a side view of the adjustable buoyancy floating fish lure of the present invention with the fishing line engaged and the buoyancy windows partially closed.
FIG. 5 is a side view of the adjustable buoyancy floating fish lure of the present invention with the fishing line engaged and noisemaking means housed within the body of the lure.
FIG. 6 is a side view of the adjustable buoyancy floating fish lure of the present invention with the fishing line engaged and scent disbursing means housed within the body of the lure.
FIG. 7 is a side view of the adjustable buoyancy floating fish lure of the present invention with the fishing line engaged and reflective attraction means housed within the body of the lure.
FIG. 7A is a side view of the adjustable buoyancy floating fish lure of the present invention with the fishing line engaged, reflective attraction means housed with the body of the lure, a further attraction means attached at one end of the lure and a hook attached along the outer surface of the lure.
FIG. 8 is a side view of the line attachment means of a second embodiment of the adjustable buoyancy floating fish lure of the present invention having an illumination means housed therein.
FIG. 9 is a side view of the second embodiment of the adjustable buoyancy floating fishing lure of the present invention prior to engagement with the fishing line, with the illumination means housed within the lure and with the buoyancy windows open.
FIG. 9A is a side view of the adjustable buoyancy floating fish lure of the present invention prior to engagement with the fishing line, with the illumination means housed within the lure, with the buoyancy windows open, and a hook attached along the outer surface of the lure.
FIG. 10 is an exploded view of the second embodiment of the adjustable buoyancy floating fish lure of the present invention.
DETAILED DESCRIPTION
The following detailed descriptions are for the best presently contemplated modes of carrying out the present invention. These descriptions are not intended in any limiting sense, but rather are made solely for the purposes of illustrating the general principles of the present invention.
Referring now to the drawings in detail, wherein like numerals indicate like elements, there is shown in FIGS. 1 and 2 , an adjustable buoyancy floating fish lure 10 having fore and aft chamber sections 20 and 30 embodying the principles of the present invention. Each chamber section 20 , 30 is coaxially disposed around a central axis 15 extending entirely through the central portion or chamber 17 of the adjustable buoyancy floating fish lure 10 . An elastic tubing 13 , such as a rubber surgical tube having a hollow interior bore connects the distal ends of the fore and aft chamber sections 20 , 30 such that the elastic tubing 13 extends through the central chamber of body 17 of the fish lure.
The fore and aft chamber sections 20 , 30 are preferably made of a transparent and colorless plastic. The light weight of the plastic, and the absence of color, permits the fish lure of the present invention to display a covert natural appearance within the water. A first end 13 a of the elastic tubing 13 is affixed to the fore chamber section 20 by a first rivet 12 a which is inserted into an opening within the fore chamber section wall 22 . The first end 13 a of the elastic tubing 13 is disposed around and between the rivet 12 a and the fore chamber section wall 22 of the opening in the fore chamber section 20 . As such, when the rivet is fully inserted into the opening in the fore chamber section wall 22 , the rivet 12 a presses the elastic tubing 13 against the fore chamber section wall 22 of the opening in the fore chamber section 20 , thereby securely holding the elastic tubing 13 in the desired position. Likewise, a second end 13 b of the elastic tubing 13 is affixed to the aft chamber section 30 by a second rivet 12 b which is inserted into an opening within the fore chamber section wall 32 . The second end 13 b of the elastic tubing 13 is disposed around and between the rivet 12 b and the aft chamber section wall 32 of the opening in the aft chamber section 30 . As such, when the rivet 12 b is fully inserted into the opening in the aft chamber section wall 32 , the rivet 12 b presses the elastic tubing 13 against the aft chamber section wall 32 of the opening in the aft chamber section 30 , thereby securely holding the elastic tubing 13 in the desired position.
Upon connecting the fore and aft chamber sections 20 , 30 by way of the elastic tubing 13 , a fishing line 11 is threaded entirely through the hollow interior of the elastic tubing 13 and first and second rivets 12 a and 12 b , respectively. As depicted in FIG. 1 , first fishing line section 11 a of the fishing line extends towards the fisherman or the fishing rod and reel assembly (not shown) and a second fishing line section 11 b of the fishing line extends towards a hook or additional fishing lure.
Positioned around the circumference of the fore chamber section 20 of the present invention are buoyancy windows 21 a-d preferably being circular in shape and extending entirely through the fore chamber section wall 22 . Each buoyancy window is positioned along the fore chamber section wall 22 at equally spaced distances so that each buoyancy window 21 a-d is separated 90 degrees along the circumference from the next buoyancy window. Thus, buoyancy windows 21 a-d are equidistantly spaced about the fore chamber section wall 22 at angles of 90, 180, 270 and 360 degrees when measured about the central axis 15 . Similarly, buoyancy windows 31 a-d of the aft chamber section 30 are equidistantly spaced about the aft chamber section wall 32 at angles of 90, 180, 270 and 360 degrees when measured about the central axis 15 .
A critical feature of the present invention is the corresponding relationship between the buoyancy windows 21 a-d of the fore chamber section 20 and the buoyancy windows 31 a-d of the aft chamber section 30 so as to adjust the buoyancy of, or air to water ratio within, the floating fishing lure 10 . The variable buoyancy of the present invention is achieved when a buoyancy window, such as 21 a of the fore chamber section 20 overlies the buoyancy window 31 a of the aft chamber section 30 . As depicted in FIG. 3 , buoyancy window 21 a and 31 a completely coincide and overlie each other and, as such, both buoyancy windows are fully aligned to create aperture valves 16 a-d having a maximum opening area. By setting the valve apertures 16 a-d to have maximum opening areas, as depicted in FIG. 3 , the floating fish lure 10 of the present invention will take on water through the valve apertures 16 a-d filling the interior chamber 17 with water and causing the fish lure 10 to sink beneath the surface of the water. Since buoyancy windows 21 a-d and 31 a-d are equidistantly spaced about the central axis 15 , the size of the valve aperture, or opening area, created by one of buoyancy windows of the fore chamber section 20 coinciding with the opening of a buoyancy window of the aft chamber section 30 will be of equal size for the other three remaining valve apertures.
Alternatively, to increase the buoyancy of the fishing lure 10 of the present invention, the size or area of the aperture valves 16 a-d must be reduced as clearly depicted in FIG. 4 . By reducing the size of the aperture valves, less water is accepted into the interior chamber 17 therefore allowing more air to remain within the interior chamber 17 so as to maintain a greater buoyancy. For instance, buoyancy window 21 a of the fore chamber section 20 only partially overlies the buoyancy window 31 a of the aft chamber section 30 , thereby creating a relatively small aperture valve 16 a compared to the aperture valve as depicted in FIG. 3 . Although not shown in the drawings, to cause the fish lure 10 of the present invention to act as a bobber and always float on top of the surface of the water, the fore and aft chamber sections 20 , 30 may be positioned relative to each other so that none of the buoyancy windows 21 a-d and 31 a-d overlie one another, resulting in the valve apertures being closed. With the valve apertures closed, water is incapable of entering the interior chamber 17 and the air within the interior chamber is incapable of escaping, thereby the fish lure 10 of the present invention will float on top of the surface of the water.
As described above, the fore and aft chamber sections 20 , 30 of the present invention are held in overlapping contact by elastic tubing 13 . The tubing 13 of the present invention has multiple advantages in that due to the hollow interior of the elastic tubing 13 the fishing line 11 can be completely inserted from the first end 13 a to the second end 13 b of the elastic tubing 13 and, by turning the fore chamber section 20 with respect to the aft chamber section 30 , thereby twisting the elastic tubing 13 , the fishing line 11 is captured and held in place within the elastic tubing 13 fixedly positioning the fish lure 10 at a predetermined distance along the fishing line 11 . A more critical feature of the elastic tube 13 is the ability to produce a contracting force to pull the fore and aft chamber sections 20 , 30 together by the twisting of the elastic tubing 13 about the central axis 15 .
Positioned on proximal end of the fore chamber section 20 , opposite the distal end where rivet 12 a is located, is a first annular serrated locking means 25 disposed along the edge of and integrally formed as part of the fore chamber section wall 22 . The serrated locking means 25 extends outwardly away from the fore chamber section 20 . Similarly positioned on the proximal end of the aft chamber section wall 32 , opposite the distal end where rivet 12 b and the buoyancy windows 31 a-d are located, is a second annular serrated locking means 35 which also extends outwardly away from the aft chamber section 30 . Both first and second annular serrated locking means 25 , 35 have the same diameter relative to the central axis 15 and each have a set of a plurality of teeth 25 a , 35 a which extend outwardly away from the fore and aft chamber sections 20 , 30 at interlocking angles.
Together with elastic tubing 13 , the first and second annular serrated locking means 25 , 35 enable a user to adjust the buoyancy of the fish lure 10 with a relatively high degree of precision. By increasing the number of teeth 25 a , 35 a extending around the first and second annular serrated locking means 25 , 35 ; the precision of buoyancy can also be increased. Likewise, reducing the number of teeth of the annular serrated locking means reduces the adjustable precision of buoyancy adjustment. Although not shown in the drawings, indicia positioned around the circumference of the either the fore or aft chamber section 20 , 30 can conceivably be incorporated thereon to indicate degrees of buoyancy, thereby enabling the user to easily adjust to a desired buoyancy.
The initial set up of the present invention begins with the insertion of the fishing line 11 into and through the elastic tubing 13 . Upon insertion of the fishing line 11 through the fish lure 10 , a user separates the fore chamber section 20 from the aft chamber section 30 by pulling each chamber in opposing directions along the central axis 15 . Once the fore and aft chamber sections 20 , 30 are separated, the elastic tubing 13 is twisted about the central axis 15 by rotating one of the fore or aft chamber sections 20 , 30 relative to the other. Although the elastic tubing 13 can be twisted in an arbitrary direction, the tube is preferably twisted in such a direction so that the teeth 25 a of the first annular serrated locking means 25 rotatably engage recesses between the teeth 35 a of the second annular serrated locking means 35 . Thus, the elastic tubing 13 securely holds the fore and aft chamber sections 20 , 30 together by not only producing a contracting force caused by the twisting of elastic tubing 13 , which forces the fore and aft chamber sections 20 , 30 together, but also produces a rotational force about the central axis 15 for engaging teeth 25 a , 35 a of the serrated locking means 25 , 35 located respectively on the fore and aft chamber sections 20 , 30 .
An additional advantageous feature of the present invention is the method of manually, and remotely adjusting the buoyancy of the floating fish lure 10 of the present invention. Although the present invention is referred to as a floating fish lure 10 , it is not limited to such, since the present invention is a multi-functioning device, in that it facilitates the placement of other fishing lures and baits through its variable buoyancy. The floating fish lure 10 is able to function as a sinker, bobber or a buoyant facilitator to enable fishing lures and baits to attain any level of buoyancy equilibrium between the fish lure 10 and the ambient water, thereby producing a natural appearance and an adjustable level of depth in the water.
As described above, the method of manually adjusting the degree of buoyancy is controlled by adjusting the coincident overlying relationship between the buoyancy windows 21 a-d and 31 a-d to produce the desired opening size of the aperture valves 16 a-d , such that the larger the opening size of the aperture valves 16 a-d , the less buoyant the fish lure 10 . Conversely, the smaller the opening size of the aperture valves 16 a-d , the higher degree of buoyancy the fish lure 10 will attain. For instance, consider the case where the valve apertures 16 a-d of the present invention are set to have a maximum opening. In this condition, upon casting the fish lure 10 into a body of water, the interior chamber 17 will fill with water causing the fish lure 10 to sink towards the bottom of the body of water due to the maximum sized valve apertures 16 a-d permitting the intake of a greater amount of water over a shorter time. Alternatively, consider the case where the valve apertures 16 a-d of the present invention are closed thereby prohibiting any amount of water passing through the valve apertures 16 a-d and into the interior chamber 17 . In this condition, the fish lure 10 will act as a bobber floating on the surface of the water. Located between these extreme conditions of the size of valve apertures 16 a-d either being fully open or completely closed, are a large number of degrees of buoyancy settings limited only by the number of teeth 25 a , 35 a of the first and second annular serrated locking means 25 , 35 . The buoyancy of the fish lure 10 is determined by the air to water ratio within the interior chamber 17 , such that the larger the amount of air, the more buoyant the fish lure becomes and conversely, the larger the amount of water versus air within the interior chamber 17 , the less buoyant the fish lure becomes. With the large number of degrees of buoyancy, a fisherman can choose just about any desired level of buoyancy.
In the situation where the fisherman is aware that the fish are feeding near the bottom of the body of water, the fisherman would set the valve apertures 16 a-d somewhere between maximum size and half-size. Continuing along the same manners of adjustments, through trial and error, the fisherman can attain the precise degree of desired buoyancy.
An additional advantageous feature of the present invention is the method of remotely adjusting the buoyancy of the fish lure 10 while the figure lure 10 is within the water. In the situation where the fisherman is aware of the presence of fish feeding in the area, but is unaware of the particular depth the fish are located, a fisherman is capable of gradually reducing the buoyancy of the fish lure by remotely jerking or jigging the lure, which forces water through the valve apertures 16 a-d and into the interior chamber 17 . This causes the air retained in the chamber 17 to bubble out and water to come into the chamber, thereby causing the fish lure 10 to sink to a slightly lower depth. For instance, with the valve apertures 16 a-d partially closed, the fish lure 10 is cast out into a body of water. Upon landing on the surface of the water, the fish lure 10 floats on top of the surface of water acting as a bobber. If the fisherman is unsuccessful in receiving any strikes from fish, the fisherman simply lightly jerks or jigs the fish lure 10 , thereby forcing a small amount of water through the valve apertures 16 a-d displacing and forcing air out of the chamber 17 . The newly added amount of water entering through the valve apertures 16 a-d and into the interior chamber 17 , increases the weight of the fish lure 10 , thereby reducing the buoyancy to a small degree and causing the fish lure 10 to sink to a slightly lower depth beneath the surface of the water. Additional slight jerks or jigs cause a tipping of the fish lure 10 permitting more water into the interior chamber 17 , causing the fish lure to sink to an even slightly deeper depth. This procedure is carried out until the fisherman approximates the appropriate depth at which the fish are feeding. By refraining from severe motions on the fish lure 10 , the lure will tend to retain its current buoyant state.
Alternatively, once the specific feeding depth is determined, the fisherman can retrieve the fish lure 10 , manually fill the interior chamber 17 with the appropriate amount of water to achieve the newly discovered degree of buoyancy for the fish lure. With the interior chamber 17 manually filled with water, the fisherman simply closes the valve apertures 16 a-d , thereby prohibiting the water from escaping out of the interior chamber 17 and again casts out into the body of water with the fish lure 10 set to the recently discovered degree of buoyancy.
To aid the fisherman in determining the amount of water to add to the interior chamber 17 of the fish lure 10 , a first set of indicia markings (not shown) representing degrees of buoyancy are disposed on the aft chamber section 30 and serve as fill lines for the fisherman. To achieve a particular degree of buoyancy, the fisherman simply adds water to the interior chamber 17 of the aft chamber section 30 until the desired degree of buoyancy is attained. Similarly, a second set of indicia markings (not shown) may be also placed on either the fore or aft chamber sections 20 , 30 to indicate degrees of buoyancy when adjusting the size of the valve apertures 16 a-d . Both first and second sets of indicia markings may be used together to determine the appropriate buoyancy required for the fish lure 10 to reach the desired feeding depth.
As depicted in FIGS. 5-7 , the adjustable buoyancy floating fish lure 10 of the present invention can incorporate additional features to increase the desirability of the lure to fish. One such feature as illustrated in FIG. 5 are noisemaking members 18 a disposed within the interior chamber 17 of the fish lure 10 . These noisemaking member 18 a are preferably made of plastic, but can conceivably be made of other various materials to aid in contributing to the production of potentially desirable noises, provided the noisemaking members 18 a do not adversely affect the overall buoyancy of the fish lure 10 . To insert the noisemaking members 18 a into the interior chamber 17 of the fish lure, fore and aft chamber sections 20 , 30 are separated and the noisemaking members 18 a are inserted through the proximal opening 36 of the aft chamber section 30 . Upon movement of the fish lure 10 of the present invention, the noisemaking members contact both the fore and aft chamber section walls 22 , 32 to produce rattling noises which will attract the attention of nearby fish.
Also used to attract the attention of fish are scent dispersing means 18 b as shown in FIG. 6 . The scent dispersing means 18 b may also be inserted into the interior chamber 17 of the fish lure 10 . A number of different types and materials of scent dispersing means 18 b can be used within the fish lure 10 provided the scent dispersing means 18 b do not adversely affect the intended functions of the fish lure 10 , such as its adjustable buoyancy. To insert the scent dispersing means 18 b into the interior chamber 17 of the fish lure, fore and aft chamber sections 20 , 30 are separated and the scent dispersing means 18 b may be inserted through the proximal opening 36 of the aft chamber section 30 . The scent from the scent dispersing means 18 b emanating from within the interior chamber 17 of the fish lure 10 seeps out and through the aperture valves 16 a-d and acts as a fish attractant for nearby fish.
As illustrated in FIG. 7 , disposed within the interior chamber 17 of the fish lure 10 is a reflective attraction means 18 c that acts to reflect light either in general, or predetermined patterns. A variety of different types of reflective attraction means 18 c are conceivable, such as but not limited to, thin metallic film such as aluminum foil, stickers or paper mediums having reflective designs replicating fish scales disposed on a surface of the medium. To insert the reflective attraction means 18 c into the interior chamber 17 of the fish lure, fore and aft chamber sections 20 , 30 are separated and the reflective attraction means 18 c is inserted through the proximal aperture 36 of the aft chamber section 30 . Flashes of light caused by the slight movement of the fish lure 10 within the water attract the attention of nearby fish.
Additional features can further be incorporated onto the fish lure 10 of the present invention to attract nearby fish, such as a skirt 19 that produces additional motion proximate to the fish lure 10 . The skirt 19 is disposed around rivet 12 b on the distal end of aft chamber section 30 and extending outwardly and away from the fish lure 10 . In order to take advantage of the situation where a fish may strike the fish lure 10 of the present invention, a hook assembly 14 is attached along the outer surface of the aft chamber section 30 . Eyelet 14 a can be affixed to aft chamber section 30 through conventional plastic welding means, or more preferably is made integrally as a unit with the aft chamber section 30 to assure a secure attachment. A conventional hook 14 c is connected to the eyelet 14 a through a link unit 14 b that is of sufficient strength to prohibit breakage under normal fishing conditions. Although the above additional fish attraction features are described separately, such features can be used separately or together, or in any conceivable combination, to attract fish, provided that such combination of features enables the fish lure 10 to carry out its intended function of adjustable buoyancy.
FIGS. 8-10 illustrate the adjustable buoyancy floating fish lure 100 of the second embodiment of the present invention, wherein a hollow attaching rod 140 is centrally disposed through fore and aft chamber sections 120 , 130 that is held in position by threaded end cap 150 . The fore and aft chamber sections 120 , 130 , as well as the hollow attaching rod 140 and threaded end cap 150 , are all preferably made of a transparent and colorless plastic which, due to the light weight of plastic and the absence of color, permits the fish lure of the present invention to display a covert natural appearance beneath the surface of the water.
As illustrated in FIG. 8 , the hollow attaching rod 140 of the second embodiment of the present invention has first and second ends 140 a and 140 b , respectively. Strategically positioned at the first end 140 a of the hollow attaching rod 140 is a line attachment means 145 . Unlike the first embodiment of the present invention, fish lure 100 connects to the fishing line (not shown in FIGS. 8-10 ) by way of a serrated gripping unit 145 b of the line attachment means 145 . The fishing line is pressed against a resilient locking unit 145 a that flexes inwardly toward the center of the hollow attaching rod 140 . Upon flexing, the displacement of the resilient locking unit 145 a creates a small gap between itself and rigid lip 145 c , thereby enabling the fishing line to pass through the gap. After the fishing line passes through the gap, the resilient locking unit 145 a returns to its initial position such that the resilient lock unit 145 a abuts against the rigid lip 145 c preventing the fishing line from escaping from the line attachment means 145 . The fishing line is then forced into the serrated gripping unit 145 b of the attaching rod 140 so that the fishing lure 100 is securely held in position on the fishing line.
The hollow attaching rod 140 of the present invention has an interior bore 146 disposed within the hollow attaching rod 140 which is sized to house an illumination means 143 . The illumination means 143 can conceivably be any illumination source, provided the illumination source is capable of fitting within the interior bore 146 of the hollow attaching rod 140 , remains illuminated for a sufficient period of time, for example one to two hours, and also does not adversely affect the adjustable buoyancy of the fish lure 100 . Preferably, the illumination source may be single use, or reusable light sticks. Placing them in low temperature environments, i.e. freezers, for future use, can reactivate the reusable light sticks 143 . Located at the second end 140 b of the hollow attaching rod 140 is an annular flange 144 that is preferably made integrally with the hollow attaching member 140 . Although not clearly illustrated in FIGS. 8-10 , the annular flange 144 has a bore equal in diameter and coaxially aligned with the interior bore 146 of the hollow attaching rod 140 . Illumination means 143 , being slightly smaller in diameter than the interior bore 146 of the hollow attaching rod 140 , is pushed into the interior bore 146 to the desired depth, and snugly held within the interior bore 146 of the hollow attaching rod 140 by a frictional fit until removed.
The fore and aft chamber sections 120 , 130 of the second embodiment of the present invention are different than the fore and aft chamber sections 20 , 30 of first embodiment of present invention. The fore chamber section 120 and the aft chamber section 130 have coaxially first and second apertures 126 a , 126 b , and 136 a , 136 b , respectively. Apertures 126 a , 126 b , 136 a and 136 b enable the hollow attaching rod 140 to initially pass through second then first apertures 136 b and 136 a on the aft chamber section 130 and extend towards and pass through the second then first apertures 126 b and 126 a of the fore chamber section 120 . Strategically positioned on the hollow attaching rod 140 , is a threaded portion 141 which protrudes through aperture 126 a on the fore chamber section. When the hollow attaching rod 140 is fully inserted through apertures 126 a , 126 b , 136 a and 136 b of the fore and aft chamber sections 120 , 130 , about a central axis 115 of the fish lure 100 , the threaded portion 141 extends beyond the fore chamber section 120 . See FIGS. 9 , 10 . Threaded end cap 150 having a bore sized to accommodate the first end 140 a of the hollow attaching rod 140 is placed over the line attachment means 145 and slid down the attaching rod 140 to engage the threaded portion 141 . By rotating the threaded end cap 150 downward, the threaded portion 141 of the hollow attaching rod 140 directly engages the threads within the bore of the threaded end cap 150 . This action exerts a force not only upon an annular rim 124 positioned on the first end 120 a of the fore chamber section 120 , but also on the second end 130 b of the aft chamber section 130 , by way of annular flange unit 144 of the hollow attaching rod 140 . As such, the rotation of the threaded end cap 150 forces both the fore and aft chamber sections 120 , 130 into direct engagement within one another.
Similar to the first embodiment of the present invention, positioned around the fore chamber section 120 of the second embodiment of the present invention are buoyancy windows 121 a-d preferably being circular in shape and extending entirely through the fore chamber section wall 122 . Each buoyancy window 121 a-d is positioned along the fore chamber section wall 122 at equally spaced distances around the periphery such that each buoyancy window 121 is positioned 90 degrees apart from the next buoyancy window 121 . Thus, buoyancy windows 121 a-d are equidistantly spaced about the fore chamber section wall 122 at angles of 90, 180, 270 and 360 degrees when measured about the central axis 115 . Similarly, buoyancy windows 131 a-d of the aft chamber section 130 are equidistantly spaced about the aft chamber section wall 132 at angles of 90, 180, 270 and 360 degrees when measured about the central axis 115 .
A critical feature of the present invention is the coincident overlying relationship between the buoyancy windows 121 a-d of the fore chamber section 120 and the buoyancy windows 131 a-d of the aft chamber section 130 to adjust the buoyancy or weight of the floating fishing lure 100 . The variably buoyancy of the present invention is achieved when a buoyancy window, such as 121 a of the fore chamber section 120 overlies the buoyancy chamber 131 a of the aft chamber section 130 . Buoyancy windows 121 a and 131 a completely overlie and are coincident with each other and as such both buoyancy windows are aligned to create aperture valves 116 a-d having a maximum opening area. By setting the valve apertures 116 a-d to have maximum area openings as depicted FIGS. 9 and 9 a , the floating fish lure 100 of the present invention takes on water through the valve apertures 116 a-d filling the interior chamber 117 with water and causing the fish lure 100 to sink beneath the surface of the water. Since buoyancy windows 121 a-d and 131 a-d are equidistantly spaced about the periphery of the fore and aft chamber sections 120 , 130 , the size of the valve aperture opening created by one buoyancy window of the fore chamber section 120 partially or completely overlying a buoyancy window of the aft chamber section 130 will cause the opening to be of equal size for the other three remaining valve apertures.
Alternatively, to increase the buoyancy of the fishing lure 100 of the present invention, the size or area of the valve aperture openings 116 a-d must be reduced as described above with respect to the first embodiment of the present invention as depicted in FIG. 4 . By reducing the size of the aperture valve openings, less water is accepted into the interior chamber 117 , therefore allowing more air to remain within the interior chamber 117 . For instance, in the situation where the buoyancy window 121 a of the fore chamber section 120 only partially overlies the buoyancy window 131 a of the aft chamber section 130 , a relatively small valve aperture opening 116 a is created when compared to the aperture valve opening 116 a as depicted in FIGS. 9 and 9 a . Although not shown in the drawings, to cause the fish lure of the present invention to act as a bobber and always float on top of the surface of the water, the fore and aft chamber sections 120 , 130 are positioned relative to each other so that neither buoyancy windows 121 a-d and 131 a-d overlie one another, thereby failing to create an valve aperture opening. Without a valve aperture opening in the present invention, water is incapable of entering the interior chamber 117 and the air within the interior chamber 117 is incapable of escaping, thereby causing the fish lure 10 of the present invention to float on top of the surface of the water.
As described above, the fore and aft chamber sections 120 , 130 of the second embodiment of the present invention are held in proximal contact by the combined elements of the hollow attaching rod 140 and threaded end cap 150 . The second embodiment of the present invention has multiple advantages, in that the buoyancy of the fish lure 100 is easily adjusted by releasing the threaded end cap 150 and modifying the relative coincident overlie of the buoyancy windows 121 , 131 of the fore and aft chamber sections 120 , 130 . Additionally, the threaded end cap 150 and threaded portion 141 of the hollow threaded rod 140 are capable of producing a strong contraction force to pull the fore and aft chamber sections 120 , 130 together by tightening the threaded end cap 150 against the annular rim 124 of the fore chamber section 120 .
Positioned on the proximal end 120 b of the fore chamber section 120 is a first annular serrated locking means 125 integrally formed as part of internal edge of the fore chamber section wall 122 and extending outwardly away from the fore chamber 120 . Similarly positioned on the exterior surface of the aft chamber section wall 132 between the proximal and distal ends 130 a , 130 b is a second annular serrated locking means 135 integrally formed as part of internal edge of the fore chamber section wall 132 and extending outwardly away from the aft chamber section 130 . Both first and second annular serrated locking means 125 , 135 are equal in diameter and have a plurality of teeth 125 a , 135 a which outwardly extend away from the fore and aft chamber sections 120 , 130 at interlocking angles.
Together with the threaded end cap 150 and hollow attaching rod 140 , the first and second annular serrated locking means 125 , 135 enable a user to adjust the buoyancy of the fish lure 100 with a relatively high degree of precision. By increasing the number of teeth 125 a , 135 a for the first and second annular serrated locking means 125 , 135 , the precision of buoyancy can also be increased. Likewise, reducing the number of teeth of the annular serrated locking means reduces the precision of buoyancy adjustment. Although not shown in the drawings, indicia positioned around the circumference of the either the fore or aft chamber sections 120 , 130 can conceivably be incorporated to indicate degrees of buoyancy, thereby enabling the user to easily adjust the fishing lure 100 to a desired buoyancy.
The initial set up of the fishing lure 100 of the second embodiment of the present invention begins with the insertion of the illumination means 143 into the interior bore 146 of the hollow attaching rod 140 the desired distance so that the light means 143 is held snugly in place by a friction fit. Prior to inserting the hollow attaching rod 140 through the fore and aft chamber sections 120 , 130 a buoyancy setting may be determined. By setting the coincident overlie of the buoyancy windows 121 a-d and 131 a-d to produce valve aperture openings 116 a-d of the desired size, the preferred degree of buoyancy for the fishing lure 100 is attained. The fore and aft chamber sections 120 , 130 are temporarily held together by abutting the first and second annular serrated locking means 125 , 135 so that the buoyancy windows 121 a-d and 131 a-d can be set to overlie each respective other by the desired amount.
Once the desired buoyancy setting is attained and the illumination means 143 is fully secured to the hollow attaching rod 140 , the first end 140 a of the hollow attaching rod 140 is inserted entirely through the distal and proximal apertures 136 b and 136 a of the aft chamber section 130 and also inserted entirely through the distal and proximal apertures 126 b and 126 a of the fore chamber section 120 . After inserting the first end 140 a of the hollow attaching rod 140 through both fore and aft chambers 120 , 130 , threaded end cap 150 is placed over the first end 140 a of the hollow attaching rod 140 so as to directly engage the threaded portion 141 of the hollow attaching rod 140 . Upon rotation of the threaded end cap 150 about the central axis 115 , the threaded end cap 150 is tightened against the annular rim 124 on the fore chamber section 120 . Further tightening of the threaded end cap 150 upon the threaded portion 141 causes the annular flange 144 to be drawn towards and abut against the distal end 130 b of the aft chamber section 130 . Additional tightening of the threaded end cap 150 causes the annular flange 144 and the threaded end cap 150 to force together the first and second annular serrated locking means 125 , 135 and tightly seal distal aperture 136 b of the aft chamber section 130 and the proximal aperture 126 a of the fore chamber section 120 to securely hold the fore and aft chamber sections 120 , 130 together.
The tightening of the threaded end cap 150 draws both the fore and aft chamber sections 120 , 130 together, thereby causing the plurality of teeth 125 a of the first annular serrated locking means 125 to directly engage recesses between the plurality of teeth 135 a of the second annular serrated locking means 135 . The combination of the threaded end cap 150 and the hollow attaching rod 140 securely hold the fore and aft chamber sections 120 , 130 together not only by a contraction force caused by relative rotation about the central axis between the threaded end cap 150 and the hollow attaching rod 140 , but also by the interlocking relationship of the plurality of teeth 125 a of the fore chamber section 120 directly engaging the recesses between the plurality of teeth 135 a of the aft chamber section 130 .
Perhaps the most critical feature of the second embodiment of the present invention is the method of adjusting the buoyancy of the fishing lure 100 of the present invention, either manually or remotely. Although the present invention is referred to as a fish lure, it is not limited to such, since the present invention is a multi-functioning device, in that it facilitates the placement of other fishing lures and baits through its variable buoyancy. The fish lure 100 is able to function as a sinker, bobber or a buoyant facilitator to enable fishing lures and baits to attain any level of buoyancy equilibrium between the fishing lure 100 and the water, thereby producing a natural appearance.
As described above, the method of manually adjusting the degree of buoyancy is controlled by adjusting the coincident overlying relationship between the buoyancy windows 121 a-d and 131 a-d to produce a specific size of aperture valve openings 116 a-d , such that the larger the size of the aperture valve openings 116 a-d , the less buoyant the fishing lure 100 will be. Conversely, the smaller the size of the aperture valve openings 116 a-d , the higher degree of buoyancy the fish lure 100 will attain. For instance, consider the case where the aperture valve openings 116 a-d of the present invention are set to have a maximum opening. In such a situation, upon casting the fish lure 100 into a body of water, the interior chamber 117 will shortly fill with water, causing the fish lure 100 to sink towards the bottom of the body of water due to the maximum sized aperture valve openings 116 a-d permitting the intake of a relatively large amount of water. Alternatively, consider the case where the aperture valve openings 116 a-d of the present invention are closed thereby prohibiting any amount of water passing through the valve apertures 16 a-d and into the interior chamber 117 . In such a situation, the fish lure would act as a bobber floating on the surface of the water. Located between the extremes of the valve aperture openings 116 a-d , either being fully open or completely closed, are a large number of degrees of buoyancy settings only limited by the number of teeth 125 a , 135 a of the first and second annular serrated locking means 125 , 135 . Within such a large number of degrees of buoyancy, a fisherman can choose almost any desired level of buoyancy. In the situation where the fisherman is aware that the fish are feeding near the bottom of the body of water, the fisherman can set the aperture valve openings 116 a-d somewhere between maximum size and half-size. Continuing along the same manners of adjustments, the fisherman can attain the precise degree of desired buoyancy.
An additional advantageous feature of the present invention is the method of remotely adjusting the buoyancy of the fishing lure 100 while in the water. In the situation where the fisherman is aware of the presence of fish feeding in the area, but is unaware of the particular depth the fish are located, the fishing lure 100 is capable of gradually reducing the buoyancy of the lure by jerking or jigging the lure, thereby forcing water through the aperture valve openings 116 a-d and into the interior chamber 117 , causing the fish lure 100 to sink to a lower depth. For instance, with the aperture valve openings 116 a-d partially closed, the fish lure 100 is cast out into a body of water. Upon landing on the surface of the water, the fish lure 100 floats on top of the surface of water acting as a bobber. If the fisherman is unsuccessful in receiving any strikes from fish, the fisherman simply lightly jerks or jigs the fish lure 100 , thereby forcing a small amount of water through the valve aperture openings 116 a-d and into the chamber 117 . The newly added amount of water entering through the valve apertures 116 a-d and into the interior chamber 117 , increases the weight of the fish lure 100 , thereby reducing the buoyancy to a small degree and causing the fish lure 100 to sink to a slightly lower depth beneath the surface of the water. Additional slight jerks or jigs force more water into the interior chamber, causing the fish lure to sink to an even slightly deeper depth. This procedure is carried out until the fisherman determines the appropriate depth the fish are feeding at. Once the specific feeding depth is determined, the fisherman can retrieve the fish lure 100 and manually fill the interior chamber 117 with the appropriate amount of water to achieve the newly discovered degree of buoyancy for the fish lure. Once the interior chamber is manually filled, the fisherman simply closes the valve apertures 116 a-d , thereby prohibiting the interexchange of water and air from escaping from the interior chamber 117 and again casts out into the body of water with the fishing lure 100 set to the desired degree of buoyancy.
To aid the fisherman in determining the amount of water to add to the interior chamber 117 of the fishing lure 100 , a first set of indicia markings (not shown) representing degrees of buoyancy may be disposed on the aft chamber section 130 and serve as fill lines for the fisherman. To achieve a particular degree of buoyancy, the fisherman simply adds water to the interior chamber 117 of the aft chamber section 130 until the water level reaches the desired fill line thereby achieving the desired degree of buoyancy. Similarly, a second set of indicia markings (not shown) may be placed on either the fore or aft chamber sections 120 , 130 indicating degrees of buoyancy when adjusting the size of the valve apertures 116 a-d . Both first and second sets of indicia markings can be used together to determine the appropriate buoyancy required to reach the desired feeding depth.
As described above with respect to the first embodiment of the present invention, fishing lure 100 of the second embodiment of the present invention can also incorporate such additional features to possibly increase the desirability of the lure to fish as shown in FIGS. 5-7 , provided the incorporation of the above mentioned additional features do not adversely affect either the functionality of the fish lure 100 or the adjustability of the buoyancy.
As illustrated in FIG. 9 a , in the case where the fisherman wishes to take advantage of the situation where a fish may strike the fishing lure 100 of the present invention, a hook assembly 114 is attached on a surface of the aft chamber section 130 . Eyelet 114 a can be affixed to aft chamber section 130 through conventional plastic welding or more preferably made integrally as a unit with the aft chamber section 130 to assure a secure attachment. A conventional hook 114 c is connected to the eyelet 114 a through a link 114 b that is of sufficient strength to prohibit breakage under normal fishing conditions. Although the above additional fish attraction features are described separately, such features can be used together in any conceivable combination to attract fish.
The present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof and, accordingly, the described embodiments are to be considered in all respects as being illustrative and not restrictive, with the scope of the invention as well as all modifications which may fall within a range of equivalency which are also intended to be embraced therein. | A floating fishing lure having the capability to adjust the buoyancy of the fish lure with a high degree of precision, such that the fish lure has fore and aft chamber sections connected and held together by an attaching means. Disposed on each fore and aft chamber sections are a plurality of buoyancy windows, one set of which will coincidentally overlie the other set of buoyancy windows as the fore chamber section is rotationally moved in regard to the aft chamber section. By changing the rotational placement of the two sections, valve aperture openings are produced that regulate the air to water ratio within the fish lure, thereby controlling its buoyancy. Additional fish attractors, hooks and illuminators can be added to the fishing lure. | 0 |
FIELD OF THE INVENTION
[0001] This invention relates to the sintering process and conditions employed in the production of fissionable nuclear fuel comprising an oxide of uranium containing an additive having a silica constituent.
BACKGROUND OF THE INVENTION
[0002] Fissionable nuclear fuel for nuclear reactors typically comprise one of two principal chemical forms. One type consists of fissionable elements such as uranium, plutonium and thorium, and mixtures thereof, in metallic, non-oxide form. Specifically this category comprises uranium, plutonium, etc. metal and mixtures of such metals, namely alloys of such metals.
[0003] The other principal type of nuclear reactor fuel consists of ceramic or non-metallic oxides of fissionable and/or fertile elements comprising uranium, plutonium or thorium, and mixtures thereof. This category of ceramic or oxide fuels is disclosed, for example, in U.S. Pat. No. 4,200,492, issued Apr. 29, 1980, and U.S. Pat. No. 4,372,817, issued Feb. 8, 1983. Uranium oxides, especially uranium dioxide, have become the standard form of fissionable fuel in commercial nuclear power plants used for the generation of electrical power. However, minor amounts of other fissionable materials such as plutonium oxide and thorium oxide, and/or neutron absorbers, sometimes referred to as “poisons”, such as gadolinium oxide, are sometimes admixed with the uranium oxide in the fuel product.
[0004] Uranium oxide fuel is generally produced by converting uranium hexafluoride or uranium metal to oxides of uranium. The process includes a series of chemical and physical operations, including pressure compacting uranium oxide in particulate form into handlable pellets or physically integrated bodies of suitable size and configuration, then sintering the resultant pellets or bodies of compacted particles. Sintering at high temperature coalesces the compacted particles of each pellet or body into an integrated unit of high density, and produces other desired effects such as manipulating the molecular oxygen content of the material and removal of residual undesirable impurities, e.g. fluorides.
[0005] Sintering processes are amply disclosed in the art, for example U.S. Pat. No. 3,375,306, issued Mar. 26, 1968; No. 3,872,022, issued Mar. 18, 1975; No. 3,883,623, issued May 13, 1975; No. 3,923,933, issued Dec. 2, 1975; No. 3,930,787, issued Jan. 6, 1976; No. 4,052,330, issued Oct. 4, 1977; and No. 4,348,339, issued Sep. 7, 1982.
[0006] Fissionable nuclear fuel materials for commercial power generating, water cooled and/or moderated reactors, commonly comprising pellets of uranium oxide, are typically enclosed within a sealed container formed of an alloy of zirconium metal, such as zircaloy-2 (U.S. Pat. No. 2,722,964), or possibly stainless steel, to provide a fuel element. The container, sometimes referred to in the nuclear field as “cladding”, generally comprises a tube-like or elongated enclosure housing fuel pellets stacked therein end-on-end to the extent of about ¾ of the length of the containers.
[0007] Fissionable fuel is enclosed and sealed in such containers for service in nuclear reactors to isolate it from contact with the coolant and/or liquid moderator. This precludes either any reaction between the fuel or fission products and the coolant or moderator media, or contamination of the coolant or moderator with escaping radioactive matter from the fuel or fission products.
[0008] Experience has shown that after extensive exposure to the radiation in the core of an operating nuclear reactor, typical fuel elements consisting of the fissionable fuel sealed within a metal container are susceptible to failures due to breaching of their containers during or following rapid power increases. Fuel container breaching has been determined to be a result of a combination of conditions, namely, stress imposed upon the metal by thermal expansion of the contained fuel, embrittlement of the metal by prolonged exposure to radiation and stress corrosion cracking susceptibility by the presence of accumulated fission products from the fuel enclosed therein.
[0009] Studies of this deleterious phenomenon have determined that three conditions contribute to produce such a failure of the metal fuel container, which is commonly referred to in the art as “intergranular stress corrosion cracking”. First, the metal must be susceptible to stress corrosion cracking in the irradiation environment; second, a level of physical stress must be present; and, third, there must be exposure to aggressive corrosive agents. Metal failure due to stress corrosion cracking can be mitigated or even eliminated by alleviating any one or more of these three conditions.
[0010] One effective means for deterring such failures in conventional fuel elements comprising zirconium alloy containers housing uranium oxide fuel has been to include a metallurgically bonded barrier liner of unalloyed zirconium metal over the inner surface of the alloy container substrate. The unalloyed zirconium metal of the barrier liner is more resistant to irradiation embrittlement than the alloy substrate whereby it retains its initial relatively soft and plastic characteristics throughout its service life notwithstanding prolonged exposure to irradiations, etc. Localized physical stresses imposed on such a barrier lined fuel container by heat expanding fuel during rapid power increases are moderated by the plastic movement of the relatively soft unalloyed zirconium metal of the liner. Moreover, the unalloyed zirconium metal has been found to be less susceptible than alloys to the effects of corrosive fission products. That is, the unalloyed zirconium has resistance to the propagation of cracks in the presence of corrosive fission products.
[0011] The effectiveness of the unalloyed zirconium barrier liners in resisting the deleterious stress corrosion cracking phenomenon due to the interaction between the fuel pellets and the container in the presence of a corrosive environment of irradiation products, is achieved by mitigating the physical stress and stress corrosion crack propagation susceptibility of the zirconium barrier layer. Effective unalloyed zirconium metal barrier linings for nuclear fuel elements comprising fuel pellets enclosed within a container are disclosed in U.S. Pat. No. 4,200,492 and No. 4,372,817.
[0012] Another approach to this problem of stress corrosion cracking as a cause of failure of fuel elements when subjected to frequent and drastic power increase has been to modify the physical properties of the uranium oxide fuel with the inclusion of additives. For example, aluminum silicates, derived from clays, when dispersed throughout the uranium oxide in amounts as low as a few tenths of one percent, have been demonstrated to be effective in increasing the plasticity of fuel pellets composed thereof, whereby the thermal expansion induced physical stress attributable to the fuel pellets is reduced. The aluminum silicate may also play a role in reducing the effectiveness and availability of the chemically aggressive fission products which promote stress corrosion cracking of the cladding tubes.
[0013] Aluminum silicate additives blended with uranium oxide have been found to be effective in eliminating or mitigating two of the three conditions which must be simultaneously present to produce stress corrosion failures in the metal of a fuel container. An aluminum silicate additive substantially increases the creep rate of fuel pellets comprising oxides of uranium and thereby reduces the stress imposed on the container due to thermal expansion of the fuel material. The enhanced plastic deformation and deformation rates attributable to this additive enables the modified fuel to flow into its own void volume or other free space in the fuel rod within the interior of the fuel container, and thereby reduce the stress applied to the cladding. Thus high localized stresses are mitigated by increased distribution of their forces.
[0014] Moreover, the aluminum silicate introduced into the fuel material reacts with fission products produced during irradiation. This reduces the concentration of aggressive fission products which, in the presence of physical stresses, are a cause of cracking, in the metal of the fuel containers.
[0015] The effects of additives comprising aluminum silicates upon fissionable nuclear fuels, including their relative quantities, are disclosed in U.S. Pat. No. 3,679,596; No. 3,715,273; No. 3,826,754; No. 3,872,022; and No. 4,052,330.
[0016] However, experience in the processing or fabrication of aluminum silicate containing ceramic fuels comprising oxides of fissionable elements employing the conventional sintering procedures and conditions used for ceramic fuel has demonstrated the occurrence of distinctive shortcomings in the resulting products. Specifically, it has been found that there occurs inconsistencies in the concentrations of aluminum silicate added and in achieving the final fuel densities desired.
[0017] The conventional sintering procedures and conditions commonly used in producing fuel with uranium oxides, such as disclosed in the foregoing patents, comprises employing reducing conditions to provide for an oxygen to metal ratio of the fuel material of near or at the desired stoichiometric composition of O/M=2.00 (UO 2 ) during and following the sintering operation. For example, hydrogen or cracked ammonia sintering atmospheres with relatively low dew points, such as <10 degrees C., or hydrogen/carbon dioxide gas mixtures or carbon monoxide/carbon dioxide gas mixtures with their ratios proportionally adjusted to produce near the stoichiometric UO 2 compositions are typically used in sintering.
[0018] Reducing conditions with high sintering temperatures, such as about 1600 degrees C. or higher result in a relatively high vapor pressure of silicon monoxide (SiO) over silicon dioxide (SiO 2 ) and aluminosilicate, amounting to as much as a few tenths of an atmosphere. See for instance “Graphical Displays of the Thermodynamics of High Temperature Gas-Solid Reactions and Their Application to Oxidation of Metals and Evaporation of Oxides” by Lou et al, Journal of the American Aramic Society , Vol. 68, No. 2 February 1985, pages 49-58.
[0019] Due to such high SiO vapor pressures, there is considerable volatilization of the silica bearing material from a uranium oxide material such as a fissionable fuel composition containing an aluminosilicate or silica bearing phase. Such a loss of silica material presents difficulties in controlling the amount of silica containing additives present in a fuel product. Moreover, because of the high vapor pressure of SiO over the silica containing additive phase, pores or voids formed within the additive phase are stabilized and achieving the desired final density is inhibited.
[0020] The disclosed contents of the foregoing United States Letters Patent, namely U.S. Pat. No. 3,375,306; No. 3,679,596; No. 3,715,273; No. 3,826,754; No. 3,872,022; No. 3,883,623; No. 3,923,933; No. 3,930,787; No. 4,052,330; No. 4,348,339; No. 4,578,229; No. 4,200,492; and No. 4,372,817, which illustrate the state of the art relevant to the invention disclosed and claimed herein, are each incorporated herein by reference.
BRIEF SUMMARY OF THE INVENTION
[0021] This invention comprises an improved method of producing nuclear fuel products comprising an oxide of uranium incorporating a silica containing additive. The invention includes a high temperature sintering procedure wherein the atmospheric composition is regulated to inhibit losses of the silica containing additive.
OBJECTS OF THE INVENTION
[0022] It is a primary object of this invention to provide an improved method of producing a fissionable nuclear fuel product comprising an oxide of uranium and a silica containing additive.
[0023] It is also an object of this invention to provide an improved procedure for sintering a nuclear fuel composition comprising an oxide of uranium and a silica containing additive in the manufacture of fissionable fuel products.
[0024] It is a further object of this invention to provide a production procedure for manufacturing nuclear fuel comprising uranium oxide with a silica containing additive which inhibits loss of the silica containing additive during sintering.
[0025] It is an additional object of this invention to provide a method for manufacturing nuclear fuel comprising uranium oxide with an aluminum silicate additive which enables governing of the product density.
[0026] It is a still further object of this invention to provide a means of impeding loss of SiO and in turn unwanted compositional changes during sintering.
[0027] It is a yet further object of the present invention to provide a method for manufacturing nuclear fuel comprising uranium oxide with an aluminum silicate additive which allows control of the aluminum-silicate content of the product.
DETAILED DESCRIPTION OF THE INVENTION
[0028] This invention deals with nuclear fuel products produced from fissionable materials comprising oxides of uranium including a silica containing additive such as disclosed in the above patents. The fissionable material, in addition to the uranium oxide and silica containing additive, can also include oxides of plutonium or thorium, neutron absorbers or “poisons” such as gadolinia, and combinations thereof, among other ingredients disclosed in the above cited prior art. The oxides of uranium and other fissionable ceramics preferably have an oxygen to metal ratio (O/M) of approximately 2.00, namely substantially composed of uranium dioxide (UO 2 ).
[0029] The silica containing additives which are a fundamental component of this invention, likewise include those disclosed, and their amounts, as given in the above cited patents. Specific silica containing additives include silicon dioxide (SiO 2 ), aluminum silicates (Al 2 O 3 .SiO 2 ), natural minerals such as mullite (3Al 2 O 3 ,.2SiO 2 ), pyrophillites (Al 2 O 3 .SiO 2 ), kaolinite (Al 2 (Si 2 O 3 ).(OH) 4 ), andalusite (Al 2 SiO 3 ), sillimanite (Al 2 SiO 5 ), and cyanite (Al 2 SiO 5 ), for example. It is also possible to employ a mixture of alumina powder and silica powder, wherein the alumina and silica are present in a ratio by weight from about 0.1 alumina to 0.9 silica to about 0.9 alumina to 0.1 silica.
[0030] Alternatively, it is possible to introduce each of the silicon and aluminum as a compound which decomposes to silica and alumina under the conditions of sintering. For example, the aluminum, or at least a portion of it, may be added as an organoaluminum compound, such as for example aluminum bistearate, diethylaluminum malonate or triphenyl aluminum. The aluminum compound, especially the bistearate, would act as a pressing die lubricant, and leave alumina when the hydrocarbon portion is volatilized. An organosilicon compound may be used for the silica addition, such as for example a volatile silicon compound that will vaporize early in the sintering process. Examples include silicobenzoic acid, triethylphenylsilicane, ethyltriphenylsilicane and methyltriphenyl silicane. The organosilicon compound would produce the fugitive silicon which would be converted to silica in the sintering furnace, and would act as a pore former to control the density and structure of the sintered pellets.
[0031] The particle sizes of the alumina and silica powders may range from about 0.01 micrometers to about 100 micrometers, more usually about 0.1 to about 10 micrometers.
[0032] The silica containing additives may be present in an amount of, for example, about 0.025 percent up to about 5.0 percent by weight of the overall fuel material. Generally the silica containing additives are present in an amount of about 0.025 percent up to about 1.0 percent by weight of the overall fuel material.
[0033] With the sintering conditions commonly employed in the manufacture of uranium oxide fuel, the vapor pressure of SiO is strongly dependent upon temperature and oxygen free energy. The process is typically carried out at a temperature of at least about 1600 degrees C., more usually at least about 1600 degrees C. At 1700 degrees C., the SiO vapor pressure can range from approximately 10 −6 (0.000001) to 10 −1 (0.10) atmospheres, note “Review-Graphic Displays of the Thermodynamics of High Temperature Gas-Solid Reactions and Their Application to Oxidation of Metals and Evaporation of Oxides”, by Lou et al, supra. At the typical sintering conditions used for urania based nuclear fuels, about 1600-1800° C., the vapor pressure of SiO is near 10 −2 (0.01) atmospheres. Under such conditions, there can occur a considerable loss of any silica bearing material.
[0034] In accordance with this invention, the oxygen free energy of the sintering atmosphere is increased during the sintering procedure. Such an increase of oxygen free energy has been determined to decrease the vapor pressure of SiO a significant amount, namely by several orders of magnitude. For instance, when the dew point of a cracked ammonia sintering atmosphere is increased from about 10 degrees C. up to about 120 degrees C., the SiO vapor pressure during sintering at about 1700 degrees C. decreases from approximately 0.1 atmospheres down to only approximately 0.0001 atmospheres. The rate of volatilization of SiO from the sintering uranium ceramic is similarly decreased by about three orders of magnitude, thus mitigating the conditions substantially responsible for the problems of composition variations and density control due to SiO vaporization. Generally, in the present invention, the sintering process for uranium oxide based nuclear fuel materials containing silicon dioxide or aluminum silicate additives is performed in an atmosphere which produces a low SiO vapor pressure by providing and maintaining the partial molar free energy of oxygen therein of greater than −90 kilocalories per mole.
[0035] Oxygen partial molar free energy can be regulated by manipulating the gas composition of the sintering atmosphere such as by applying specific gases and or by proportioning the ratios of mixtures of gases. For example, the sintering atmosphere conditions can be achieved through the application of wet hydrogen, wet cracked ammonia (or 25% nitrogen-75% hydrogen), mixtures of carbon monoxide/carbon dioxide gases and mixtures of hydrogen/carbon dioxide gases in appropriate ratios.
[0036] Generally, sintering temperatures for the practice of this invention fall within a range of from about 1600 degrees C. up to about 2200 degrees C. More usually, the sintering is carried out within the range of about 1600 degrees C. to about 2000 degrees.
[0037] The invention will now be described with reference to the following non-limiting example.
EXAMPLE
[0038] Alumina and silica powders in a weight ratio of 0.4 Al 2 O 3 /0.6 SiO 2 are blended with uranium dioxide powder to achieve a total addition of 0.25 wt % of the alumina/silica with 99.75% uranium dioxide. The blended powders are dry-pressed to a green density of approximately 5.6 gm/cm 3 to form powder compacts in the form of right circular cylinders for sintering to fuel pellets.
[0039] The dry pressed pellets are sintered using a furnace feed gas of 75% hydrogen-25% nitrogen which has been moisturized by passing the gas through a water bubbler with the temperature of the water in the bubbler maintained at 55° C. and a total furnace gas pressure of 1 atmosphere (760 mm Hg). At 55° C., the vapor pressure of water is 118 mm Hg, the hydrogen and nitrogen gas pressures of the furnace feed gas are 481.5 and 160.5 mm Hg, respectively, and the H 2 O to H 2 ratio of the furnace gas atmosphere is 118/481.5=0.245.
[0040] The sintering furnace temperature profile is maintained to provide prolonged (˜4 hours) sintering at 1750° C. in the hot or working zone of the sintering furnace. At that sintering temperature, for the H 2 O to H 2 ratio noted above, the oxygen free energy in the hot zone of the sintering furnace is maintained at about −70 kcal/mole, the O/U ratio of the uranium oxide during the sintering operation is maintained at about 2.005, and the vapor pressure of SiO is maintained at about 10 5 (0.00001) atmospheres. For these sintering conditions, the desired final fuel pellet density of 10.5 gm/cm 3 is achieved, and the aluminum and silicon contents of the final sintered pellets are within acceptable ranges of the initial amount added.
[0041] While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, it is to be understood that the invention is not to be limited to the disclosed embodiment, but on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims. | Improved method of sintering for the manufacture of nuclear fuel comprising a fissionable ceramic material including a silica containing additive. The method includes controlling the sintering atmosphere to impede loss through vaporization of the silica. | 6 |
RELATED APPLICATION
[0001] The present applications relates to, and claims priority from, provisional application serial No. 60/424,263, filed on Nov. 6, 2002, titled “CONTACT FOR HIGH SPEED SMALL FORM FACTOR PLUGGABLE CONNECTOR”, the full and complete subject matter of which is expressly hereby incorporated in its entirety by reference.
BACKGROUND OF THE INVENTION
[0002] The present invention generally relates to a contact and a connector configured to carry data at high speeds. More specifically, certain embodiments of the present invention relate to a contact for use in connectors, such as in small form factor pluggable connectors.
[0003] Recently, interface connectors have been developed that are capable of satisfying a common specification for multi-source applications, such as in the telecommunications field, data communications applications, storage area networks and the like. The connectors convey data at very high data rates and should satisfy very strict signal quality criteria. The connectors are used in applications that have very demanding space constraints and thus are developed to satisfy a small form factor.
[0004] These connectors interconnect a variety of components, such as host boards and daughter boards that carry transceiver ASICs and the like. In certain applications, the connector may be a 20 to 70 position pluggable transceiver (PT) connector that carries digital data signals at high data rates, such as 2.5, 5, and 10 Gbps or higher.
[0005] However, as data rate increases, the signal performance of the conventional connectors declines. The signal performance may be characterized in terms of jitter, return loss, insertion loss, attenuation, reflectance, signal to noise ratio and the like. The performance of the connector is affected by several factors, one factor of which is the shape and configuration of the contacts that carry the data signals through the connector. Contacts of conventional design have been found to exhibit declining performance characteristics once the data rate reaches and exceeds 5 or 10 Gbps and higher.
[0006] [0006]FIG. 9 illustrates a conventional contact 310 designed for small form factor pluggable connectors to carry digital signals at a data rate of up to 2.5 Gbps. The contact 310 is held in a housing of a connector 305 . The contact 310 includes a contact beam 312 that is joined to one end of a leg portion 320 . An opposite end of the leg portion 320 joins a tail portion 332 . The contact beam 312 and tail portion 332 define interfaces at which data signals are conveyed to mating contact pads 357 and 355 on a module board 358 and host board 354 , respectively. The contact 310 includes a retention stub 322 that holds the contact 310 in place in the connector 305 . The retention stub 322 includes a base end formed with the leg portion 320 at an intermediate point along the length of the leg portion 320 . The retention stub 322 projects at a right angle from the leg portion 320 with an outer end 324 terminating at a point remote from the contact 310 .
[0007] The contact 310 exhibits satisfactory performance at data rates of at least 2.5 Gbps. However, when the data rate is increased to near 10 Gbps and higher the retention stub 322 begins functioning as an electrical stub which causes signal degradation, such as increased jitter, insertion loss, return loss and the like.
[0008] A need exists for an improved contact configuration that overcomes the problems noted above and experienced heretofore by convention contacts.
BRIEF SUMMARY OF THE INVENTION
[0009] A contact is provided for use in an interface connector, such as a small form factor pluggable connector. The contact comprises a contact beam having a mating surface proximate a first end of the contact beam. The contact beam is configured to carry high speed data signals. The contact further includes a tail portion configured to carry high speed data signals. A leg portion of the contact joins and interconnects the tail portion and a second end of the contact beam. The leg portion includes a retention segment, through which a signal transmission path passes as data signals are carried through the leg portion between the tail portion and contact beam. The retention segment is configured to secure the leg portion within a connector.
[0010] Optionally, the retention segment many be U-shaped and include first and second stems extending parallel to one another and being joined at one end. The stems are open at an opposite end, at which the first and second stems join the tail portion and leg portion, respectively. The signal transmission path passes through the first and second stems continuously along the U-shape. When the retention segment is formed in a U-shape, the contact's overall shape forms a general S-shape through which the signal transmission path travels.
[0011] In accordance with an alternative embodiment, a small form factor pluggable connector is comprised of a housing having first and second ends configured to mate with adjoining elements, such as module and host boards. The connector includes a contact held in the housing that has a contact beam configured to join a contact pad on an adjoining element. The contact includes a tail portion also configured to join a contact pad on an adjoining element. The contact beam and tail portion are joined by a leg portion that includes a retention segment formed continuously within the signal transmission path through the leg segment between the tail portion and contact beam. The retention segment secures the leg portion within the housing.
[0012] In accordance with an alternative embodiment, a method is provided for transmitting a high speed data signal in a carrier wave through contacts in a small form factor pluggable connector. The method comprises transmitting data signal pairs in a high speed data signal over contacts in a small form factor pluggable connector at a data rate of at least 10 Gbps. The method further includes directing the data signal pairs along corresponding signal transmission paths through corresponding contacts that maintain a predetermined signal performance such that the jitter of the data signal pair at the contacts does not substantially exceed 11 picoseconds.
[0013] In accordance with at least one alternative embodiment, a method is provided for transmitting a high speed data signal in a carrier wave through contacts in a small form factor pluggable connector. The method comprises transmitting a data signal in a high speed data signal over a contact in a small form factor pluggable connector at a data rate of approximately at least 10 Gbps (e.g., 9.9-10.7 Gbps). The method further includes directing the data signal along a signal transmission path through the contact that maintains a predetermined signal performance such that insertion loss does not substantially exceed −3 dB up to the third harmonic (e.g., 15 GHz) of the fundamental frequency (e.g., 5 GHz) of the 10 Gbps data rate.
[0014] In accordance with an alternative embodiment, a method is provided for transmitting a high speed data signal and carrier wave through a contact in a small form factor pluggable connector. The method comprises transmitting a data signal in a high speed data signal over a contact in a small form factor pluggable connector at a data rate of at least 10 Gbps. The method includes directing the data signal along a signal transmission path through the contact that maintains a predetermined signal performance such that the return loss does not substantially exceed the insertion loss for frequencies between 5 and 15 GHz.
BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWINGS
[0015] [0015]FIG. 1 illustrates an isometric view of a contact formed in accordance with an embodiment of the present invention.
[0016] [0016]FIG. 2 illustrates a side sectional view of a contact held in a connector formed in accordance with an embodiment of the present invention.
[0017] [0017]FIG. 3 illustrates a graph plotting insertion loss at various data rates experienced by the contact of FIG. 1 versus the contact of FIG. 9.
[0018] [0018]FIG. 4 illustrates a graph plotting return loss at various data rates experienced by the contact of FIG. 1 versus the conventional contact of FIG. 9.
[0019] [0019]FIG. 5 illustrates an eye pattern representing the performance exhibited by a reference cable carrying data signals at 10 Gbps.
[0020] [0020]FIG. 6 illustrates an eye pattern representing the performance exhibited by the conventional contact of FIG. 9 carrying data signals at 10 Gbps.
[0021] [0021]FIG. 7 illustrates an eye pattern representing the performance exhibited by a reference cable carrying data signals at 10 Gbps.
[0022] [0022]FIG. 8 illustrates an eye pattern representing the performance exhibited by the contact of FIG. 1 formed according to an embodiment of the present invention carrying data signals at 10 Gbps.
[0023] [0023]FIG. 9 illustrates a side section view of a conventional contact held in a connector.
[0024] The foregoing summary, as well as the following detailed description of certain embodiments of the present invention, will be better understood when read in conjunction with the appended drawings. For the purpose of illustrating the invention, there is shown in the drawings, certain embodiments. It should be understood, however, that the present invention is not limited to the arrangements and instrumentality shown in the attached drawings.
DETAILED DESCRIPTION OF THE INVENTION
[0025] [0025]FIG. 1 illustrates a contact 10 formed in accordance with an embodiment of the present invention. The contact 10 is configured to be secured in a housing of a connector, such as a small form factor pluggable connector. The contact 10 may be used in a variety of other connectors and applications that convey signals at high data rates and desire high quality signal performance. By way of example, the contact 10 may carry digital data having a fundamental frequency of 5 GHz and a data rate of 10 Gbps and higher, while exhibiting very little jitter, insertion loss and return loss.
[0026] The contact 10 includes a contact beam 12 having an outer end with an optional lead-in surface 14 adjacent a mating surface 16 . The lead-in surface 14 is curved upward to facilitate loading of another component, such as a host board, daughter board and the like. When the host board or other component is fully inserted, contact (mating) pads on the host board firmly engage the mating surface 16 in a tangential alignment. Optionally, the mating surface 16 may be on the top or outer end of the contact beam 12 , or may constitute a pin insertable into an adjoining contact.
[0027] The contact 10 also includes a leg portion 20 having one end joined at bend 18 with the contact beam 12 . The leg portion 20 has an opposite end joining a tail portion 32 that may extend beyond a rear face 60 of the contact 10 . As shown in FIG. 2, the tail portion 32 extends beyond the rear end 60 of the connector 50 into which the contact 10 is loaded. While tail portion 32 is shown bent to extend beyond the contact 10 , optionally the tail portion 32 may be 1) bent in the opposite direction under the contact 10 , 2) shortened to be even with rear face 60 , or 3) turned downward to serve as a pin or otherwise. The tail portion 32 is configured to join a contact pad on a mating component, such as a host board 54 and the like. Optionally, the tail portion 32 may be soldered, surface mounted, or inserted as a pin to join with the host board 54 .
[0028] The leg portion 20 includes a brace segment 34 having an upper end joining the contact beam 12 generally at a right angle. A lower end of the brace segment 34 is formed at bend 28 with a retention segment 22 . The retention segment 22 is configured to securely retain the contact 10 in a channel within the housing of a connector 50 (FIG. 2). The brace segment 34 spaces the contact beam 12 and retention segment 22 apart from one another by a distance sufficient to define a mating area 30 therebetween. A module board 58 (FIG. 2) is inserted into the mating area. The retention segment 22 is oriented parallel to, and extends in the same direction as, the contact beam 12 . The retention segment 22 is generally U-shaped and includes upper and lower stems 26 and 27 , respectively. First ends of the upper and lower stems 26 and 27 are joined to one another proximate the contact beam 12 , while opposite rear ends 38 of the upper and lower stems 26 and 28 are open. The rear end 38 of the lower stem 28 joins the tail portion 32 , which extends downward and rearward in a stepped manner.
[0029] Optionally, the retention segment 22 may extend in the direction opposite to the contact beam 12 . Alternatively, the retention segment 22 may be oriented at an acute or obtuse angle with the contact beam 12 . The retention segment 22 may have other shapes, such as C-shaped, S-shaped, square, arc-shaped, triangular, and the like.
[0030] The upper and lower stems 26 and 27 provide an opening at the rear end 38 to define a signal transmission path through the entire retention segment 22 (as denoted by arrow A) that is continuous, uninterrupted and lacking in termination points. When data signals are conveyed through the contact 10 , they pass from the mating surface 16 along the contact beam 12 , through the brace segment 34 , and around the upper stem 26 and lower stem 27 until reaching the tail portion 32 . Of course, data signals may be conveyed in the reverse direction instead, beginning at the tail portion 32 and traveling to the contact beam 12 .
[0031] The upper stem 26 includes projections 36 formed on the upper edge thereof. The projections 36 are dimensioned such that they, in combination with a lower edge 29 of the lower stem 27 , form an interference fit within a channel in the connector.
[0032] [0032]FIG. 2 illustrates a side sectional view of a connector 50 that may utilize the contact 10 . The connector 50 includes a base 52 mounted on a host board 54 and includes a front face 56 that receives a module board 58 . The connector 50 includes a rear face 60 having a passage 62 formed therein that extends to the front face 56 . The contact beam 12 extends into the passage 62 to a depth proximate the front face 56 . The rear face 60 also includes a channel 64 that is dimensioned to firmly receive the retention segment 22 . The tail portion 32 is mounted to a contact pad 55 on the host board 54 , while the mating surface 16 on the contact beam 12 abuts against a contact pad 57 on the module board 58 . Optionally, a pin 66 may be mounted in the host board 54 to retain the connector 50 thereon.
[0033] [0033]FIG. 3 illustrates a graph plotting insertion loss in decibels (dB) on the vertical axis and frequency in Gigahertz (GHz) on the horizontal axis. Insertion loss represents an attenuation of the data signal that results from the addition of a device into a system characterized as a transmission line. The insertion loss represents the reciprocal of the ratio of 1) the signal power delivered to the point in the transmission line where the device is added and 2) the signal power at the same point in the transmission line before the device is added.
[0034] In FIG. 3, line 80 represents the insertion loss introduced by contact 10 (FIG. 2) into a data signal carrying data at a rate of approximately 10 Gigabits per second (Gbps). The insertion loss of contact 10 is measured at the contact pad 57 on the module board 58 (FIG. 2) and the contact pad 55 on the host board 54 . The line 82 represents the insertion loss introduced by contact 310 (FIG. 9) into a data signal also carrying data at a rate of approximately 10 Gbps. The insertion loss of contact 310 is measured at the contact pads 357 and 355 on the module board 358 and host board 354 , respectively.
[0035] It is understood that the data signal is comprised of frequency components spanning a broad frequency range. Each frequency component experiences insertion loss to a different degree. In FIG. 3, the insertion loss is shown for the frequency components, between 0 and 16 GHz, that are comprised in a data signal having a 10 Gbps data rate. For example, the 2 GHz frequency component conveyed through contacts 10 and 310 experiences very little insertion loss. The frequency components between 7 and 8 GHz, conveyed through contacts 10 and 310 experience approximately 1 dB of insertion loss. Of particular interest, the insertion loss introduced by contact 10 does not substantially exceed −2.5 dB for any frequency component up to 12.5 GHz, and does not substantially exceed −3 dB for any frequency component up to 16 GHz. It should be noted that 10 GHz and 15 GHz frequency components are the second and third harmonics of the fundamental frequency (5 Ghz) of the data signal. As is apparent from FIG. 3, the conventional contact 310 exhibits substantially more insertion loss at frequencies above 10 GHz as compared to contact 10 .
[0036] [0036]FIG. 4 illustrates a graph plotting return loss in dB on the vertical axis and frequency in GHz on the horizontal axis. Return loss represents a summation of the reflected signal energy returning backward toward an end of a transmission line from which the signal originates (e.g., an echo signal). For example, in bi-directional signaling applications, a transceiver may be placed at each end of the transmission line. The transmitter within each transceiver sends a data signal through the transmission line and then begins “listening” over the same line for data that is transmitted from the opposite end. The reflected or echo signals interfere with the desired data signals. Return loss may be caused by discontinuities and impedance mismatches within the transmission line. For purposes of this exemplary embodiment, it may be assumed that the data path between the module board 58 , contact 10 and host board 54 form a transmission line. Discontinuities within a transmission line occur at connection points, such as at contact pad 57 and at contact pad 55 . Impedance mismatches may occur between components within a transmission line or within a single component, device or cable.
[0037] In the conventional contact 310 (FIG. 9), the retention stub 322 functioned as an electrical stub for the higher frequency components of the data signal. As the retention stub 322 functioned more and more as an electrical stub, it varies the electrical characteristics of the contact 310 including, among others, its impedance. As the electrical characteristics (such as, but not limited to, the impedance) of the contact 310 vary, insertion loss, return loss and the like increase. The line 90 (in FIG. 4) represents the return loss of contact 10 (FIG. 1) measured at and including the contact pad 57 on the module board 58 and, at and including the contact pad 55 on the host board 54 while carrying digital data signals at approximately 10 Gbps (e.g., 9.9-10.7 Gbps). The line 92 represents the return loss of a contact 310 (FIG. 9) measured at the contact pads 357 and 355 .
[0038] [0038]FIG. 4 illustrates the frequency components between 0 and 16 GHz that comprised a data signal having a 10 Gbps data rate. The return loss of the contact 10 for the 5 GHz frequency component is no greater than −15 dB. The return loss of the contact 10 for the 10 GHz and 15 GHz frequency components at do not exceed −5 dB and −2.5 dB, respectively. The frequency components at 5 GHz, 10 GHz and 15 GHz represent the fundamental, second harmonic and third harmonic frequencies of the exemplary data signal.
[0039] The measurements plotted in FIGS. 3 and 4 are taken at the contact pads 55 , 355 , 57 and 357 to account for the interconnections at the tail portions 32 , 322 and mating surfaces 16 , 316 . The contact pads 55 and 355 may represent solder pads, while the contact pads 57 and 357 may represent mating pads.
[0040] FIGS. 5 - 8 illustrate eye patterns for reference cables (FIGS. 5 and 7), the conventional contact 310 (FIG. 6), and contact 10 (FIG. 8). The eye patterns in FIGS. 5 and 7 represent the data signal introduced into the contacts 310 and 10 . An eye pattern represents an oscilloscope display in which a pseudo-random digital data signal from a receiver is repetitively sampled and applied to the vertical input of the oscilloscope, while the data rate is used to trigger the horizontal sweep of the oscilloscope. In the example of FIGS. 5 - 8 , the data rate is 5 Gbps. The reference signal included a data stream containing pseudo-randomly generated data words, where each data word contained 127 bits (2 7 −1 PRBS). The data signal was driven by a 5 GHz clock to produce a 10 Gbps data rate. As shown in FIGS. 5 and 7, the reference cables (without any contact attached thereto) exhibited a 9 ps (picosecond) jitter and contained an 887 mV eye amplitude).
[0041] With reference to FIG. 5, the eye pattern 500 includes top and bottom rails 502 and 504 , respectively. The distance 506 between the centers of the top and bottom rails 502 and 504 corresponds to the signal amplitude. The thickness or width of each of the top and bottom rails 502 and 504 corresponds to the noise amplitude. The eye opening 508 represents the distance between the top and bottom rails 502 and 504 . The temporal width (along the horizontal axis) of the crossing section 510 represents the amount of jitter in the signal. In the referenced cable of FIG. 5, the eye opening 508 has a value of 887 mV, while the jitter 510 has a value of 9 ps.
[0042] The rising edge 512 of the reference cable in FIG. 5 completes a state transition of approximately 800 mV in approximately 45 ps (the divisions on the horizontal axis are 15 ps/division, and on the vertical axis are 200 mV/division. FIG. 7 illustrates the performance of a reference cable substantially similar to that of FIG. 5, but attached to the contact 10 (shown in FIG. 1). The signal performance of the reference cable in FIG. 7 exhibits an eye opening of 887 mV and a jitter of 9 ps.
[0043] With reference to FIG. 6, the conventional contact 310 exhibits an eye opening having a value of 808 mV, with a jitter equal to 12 ps. In addition, FIG. 6 illustrates the rising edge 612 of the data signal passed through conventional contact 310 . The rising edge 612 of the data signal through contact 310 requires over 75 ps to complete the state transition of approximately 800 mV.
[0044] In FIG. 8, the contact 10 (FIG. 1) exhibits a signal performance having an eye opening of 756 mV and a jitter of approximately 10 ps. In addition, the rising edge 812 of the data signal is less rounded as compared to the rising edge 612 (FIG. 6) of the conventional contact 310 . The rising edge 812 of the data signal through contact 10 requires no more than 60 ps to complete the state transition. The data signal conveyed by contact 10 exhibits a steeper or faster rise/fall time to transition between states as compared to the conventional contact 310 . A steeper rise time affords more time for the transceiver circuitry to gate or acquire each data value (e.g., a logic 0 or a logic 1) in the data signal. The improvement in rise time is due in part to the reduction, by the contact 10 , of insertion and return losses. By reducing the insertion and return losses, the signal quality is improved which in turn affords a steeper or faster rise/fall time, reduces jitter and introduces less distortion.
[0045] As shown above, the insertion and return losses are reduced by providing an electrical contact with more stable electrical characteristics over a wider frequency range. By way of example, the contact 10 exhibits a substantially even impedance along its length and over a large frequency range, up through the third harmonic of the fundamental frequency of the data transmission rate. For example, a data rate of 10 Gbps which is driven by a clock operating at 5 GHz per second has a third harmonic of approximately 15 GHz. As shown in FIGS. 3 and 4, the insertion and return loss (lines 80 and 90 ) of contact 10 maintained a much more stable and even performance over frequencies of 5 GHz and higher, as compared to the insertion and return losses ( 82 and 92 ) exhibited by the conventional contact 310 . At frequencies above 5 and 10 GHz, the retention stub 322 (FIG. 9) of the conventional contact 310 begins functioning as an electric stub. As an electrical stub, the retention stub 322 begins operating as a parallel transmission line that progressively interferes more with the characteristics of the higher frequency components. By way of example, when the length of the retention stub 322 equals ¼ th of the wave length, the retention stub 322 forms a short circuit which drastically degrades the operation of the contact 310 .
[0046] The contact 10 (FIG. 1) avoids stubs or other structure that would otherwise operate as an electrical stub, thereby avoiding the problems experienced by the conventional contact 310 . The structure of the contact 10 supports data transmission at high frequencies (as shown in FIGS. 3 and 4) with less insertion and return loss, thereby improving the signal quality and affording a steeper/faster rise/rise time for the transition of the data signal between states, as well as reducing jitter and introducing less distortion.
[0047] While the invention has been described with reference to certain embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted 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 its scope. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed, but that the invention will include all embodiments falling within the scope of the appended claims. Optionally, multiple contact 10 may be held in a common housing and configured to transmit data signal pairs. | A contact is provided for use in an interface connector. The contact comprises a contact beam 12 having a mating surface proximate a first end of the contact beam. The mating surface 16 is configured to join a contact pad, such as on a module board to carry high speed data signals therebetween. The contact further includes a tail portion configured to join a contact pad, such as on a host board. A leg portion of the contact joins and interconnects the tail portion and a second end of the contact beam . The leg portion includes a retention segment , through which a signal transmission path passes as data signals are carried through the leg portion between the tail portion and contact beam, thereby reducing signal degradation. The retention segment is configured to secure the leg portion within a connector. | 7 |
RELATED APPLICATIONS
[0001] This application claims the priority of Provisional Patent Application Serial No. 60/248,918 on Nov. 15, 2000.
BACKGROUND OF THE INVENTION
[0002] The present invention generally relates to elevator car door opening and closing apparatus. More specifically the present invention relates to an elevator car door opening apparatus wherein the active door operating mechanism is carried upon the elevator car and car door and an inexpensive, landing door unlocking and opening mechanism is attached to the landing door. A mechanical elevator car door locking mechanism is included which is inherently disabled when the car is within a reasonable distance of a landing site but which otherwise only permits the doors to be opened by an amount insufficient for passengers, within the car, to exit.
PRIOR ART
[0003] Heretofore complex and expensive landing door opening mechanisms have been attached to the landing door at each individual landing site. An example of such a mechanism may be found in U.S. Pat. No. 5,690,188, for an “Elevator Door System” issued to Takakusaki et al. on Nov. 25, 1997 wherein simple, inexpensive car door opening roller assemblies are placed on the car doors and complex, expensive, vane assemblies are placed on each landing site door. This arrangement can prove very costly in a high rise building having a large number of floors served by multiple elevators since the expensive vane assemblies must be provided on each and every landing site door.
BRIEF SUMMARY OF THE PRESENT INVENTION
[0004] The present invention overcomes the shortcomings of the referenced prior art by placing relatively inexpensive landing door opening roller assemblies on the landing doors and placing a more efficient clutch assembly on the elevator car door that engages the landing door roller assembly when the car doors are opened thereby opening both car and landing doors simultaneously in a more efficient and economical manner. Therefore, the more expensive clutch assembly need only be provided on the elevator car and not on each and every landing site door; a definite economical advantage in high rise buildings having a large number of landing sites served by one or more elevator cars.
[0005] The present invention teaches a new and improved clutch assembly, attached to the elevator car door comprising an assembly of mechanical links that form an expanding and collapsing mechanical parallelogram that is linked to the car door opening mechanism. The mechanical parallelogram is configured such that two parallel sides thereof provide a pair of vertically oriented gripping links that move laterally toward or away from each other as the mechanical parallelogram expands or collapses. A cam wheel, operated by the door opening mechanism, expands and/or collapses the mechanical parallelogram.
[0006] As the elevator car approaches and stops at a landing site, a pair of rollers attached to the landing door's locking mechanism enters the slot between the vertically oriented gripping links of the mechanical parallelogram. As the elevator doors begin to open, by action of the car door opening mechanism, the cam wheel is caused to rotate thereby collapsing, or closing, the vertical gripping links upon the landing door rollers coupling the landing door to the elevator car door and unlocking the landing doors. With the landing doors unlocked and coupled to the elevator car doors, the car doors and landing doors are opened simultaneously by the car door opening mechanism.
[0007] By reversing the elevator car door opening mechanism, the elevator car doors and the landing doors are simultaneously closed and the gripping links are expanded or opened, by the reverse rotation of the cam wheel, thereby releasing their grip upon the landing door rollers whereby the landing doors are again locked and the elevator car is free to move on to another landing site.
[0008] In the event of an emergency such as an unexpected electrical power failure, the door opening system, as taught and disclosed herein, further provides a simple and economical way to prevent the opening of the elevator car doors, by onboard passengers, beyond a predetermined amount if the elevator car is not within reasonable distance of a landing zone.
[0009] If the elevator car is not within a reasonable distance of a landing site the landing door locking and unlocking rollers will not be between the vertical gripping links of the mechanical parallelogram. Therefore, if the passengers, in a stalled elevator car, push the car doors open, the gripping links, of the mechanical parallelogram will close or collapse toward each other farther than possible when the landing door locking and unlocking rollers are present. The additional travel of the mechanical parallelogram gripping links may be advantageously used to mechanically activate, by appropriate mechanical linkage, a car door latch mechanism that will limit the amount of car door separation.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] [0010]FIG. 1 presents a view looking downward on the top of a typical elevator car, embodying the present invention, stopped at a landing site.
[0011] [0011]FIG. 2 presents an elevational, view of a pair of elevator car doors in the closed configuration and embodying the present invention.
[0012] [0012]FIG. 3 presents an elevational view of a pair of elevator car doors in the open configuration and embodying the present invention.
[0013] [0013]FIG. 4 presents a pictorial view of the elevator door power drive assembly of the present invention.
[0014] [0014]FIG. 5 presents an elevational view of the right side car door embodying the present invention.
[0015] [0015]FIGS. 5A through 5C illustrates the operation of an elevator car door safety latch.
[0016] [0016]FIG. 6 presents an enlarged elevational view of the door opening clutch assembly shown in FIG. 5.
[0017] [0017]FIG. 7 presents an exploded view of the elements comprising the car door opening clutch assembly as illustrated in FIGS. 5 and 6.
[0018] [0018]FIG. 8 presents a plan view of the landing door opening rollers about to be engaged by the elevator door opening clutch assembly
[0019] [0019]FIG. 9 presents an elevational view taken along line 9 - 9 in FIG. 6.
[0020] [0020]FIG. 10 presents an elevational view taken along line 10 - 10 in FIG. 6.
[0021] [0021]FIG. 11 presents an elevational view taken along line 11 - 11 in FIG. 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0022] [0022]FIG. 1 presents a top view of a typical elevator car 10 positioned at a typical landing site and embodying the present invention. As illustrated, in FIG. 1, the elevator car doors 12 and 13 are in alignment with landing doors 14 and 15 respectively. A door opening clutch assembly 18 , attached to each car door 12 and 13 , is in engaging alignment with a pair of landing door unlocking and opening roller assemblies 21 .
[0023] When car 10 stops at a given landing, car doors 12 and 13 are opened by means of clutch assemblies 18 which, because of their engagement with roller assemblies 21 on landing doors 14 and 15 also unlock and open landing doors 14 and 15 .
[0024] Referring now to FIG. 2, car doors 12 and 13 are illustrated in their closed position. A door opening power drive assembly 40 is affixed to the top of car 10 . Referring now to FIG. 4, drive assembly 40 preferably comprises an electric motor 42 coupled to a speed reducing torque multiplier 44 preferably having a speed reduction ratio of 29 to 1. Although any speed reducing apparatus may be used it is preferable that a “cyclo” or cyclodial type speed reducer be used. A suitable cyclo speed reducer has been found to be Cyclo Speed Model CNHX-4100Y-29 marketed by Sumitomo Machinery Corporation of America. The cyclo speed reducer operates by the action of an eccentric cam mounted on the input shaft of the speed reducer. The eccentric cam rotates within a bore inside a cyclodial disc forcing the cyclodial disc to roll inside a ring gear housing. As the input shaft, and the eccentric cam, rotate, the cyclodial disc advances a given distance in the opposite direction thereby producing a speed reduction. The amount of speed reduction is determined by the specific design of the cyclodial disc and the ring gear housing. The primary advantage of the cyclodial speed reducer is that it has no elements operating in shear as in a typical geared speed reducer. In a cyclodial speed reducer all moving elements operate in compression. Thus a valuable benefit is realized, namely long life and no catastrophic failure is possible. Further, because of the rolling action, the cyclo speed reducer is more quiet than speed reducers using gears. This is particularly important for a device mounted on top of an elevator car where because of its box like structure, can amplify sounds to the passengers within the car.
[0025] Attached to output shaft 46 of speed reducer 44 is a typical door actuating arm 48 having a typical counter weight 41 attached thereto as illustrated. However, any other traditional drive assembly, such as the belt drive assemblies as illustrated in U.S. Pat. Nos. 4,926,975 and 5,690,188, may be used in combination with the present invention.
[0026] The continuing detailed description of the present invention will be further described as it applies to the right hand elevator door 13 and its associated landing door 15 . However, it is to be understood that the invention, hereinbelow, may be equally applied to the left hand door 12 , as also illustrated in the figures, by one skilled in the relevant art.
[0027] Referring now to FIGS. 2, 5, and 6 , door drive link 20 is pivotally attached to pivot pin 43 of actuating arm 48 of power drive assembly 40 . Link 20 is pivotally attached to door opening link 22 at pivot 23 . Door opening link 22 is pivotally attached to the car body at pivot 24 . Link 22 is also pivotally attached to rotatable cam link 60 , of clutch assembly 18 , at pivot 51 . Rotatable cam link 60 is pivotally attached to clutch mounting plate 62 by pivot pin 54 . Clutch mounting plate 62 is typically attached to door 13 , as illustrated in FIG. 5, by any convenient means. FIG. 7 provides an exploded view of clutch assembly 18 as applied to door 13 .
[0028] To open doors 12 and 13 , power drive assembly 40 is energized whereby actuating arm 48 rotates counterclockwise, as viewed in FIG. 2, thereby causing link 20 to translate to the left whereby link 22 rotates, counterclockwise about pivot 24 dragging door 13 to its open position as illustrated in FIG. 3. To close doors 12 and 13 , the process is simply reversed.
[0029] Referring now to FIGS. 2, 3, 5 , 6 , 7 , 9 and 10 . Clutch assembly 18 , preferably, comprises a base or mounting plate 62 which is affixed to the hoist side of elevator door 13 . Pivotally attached to base plate 62 are a pair of laterally disposed, diagonal links 71 and 72 . Diagonal links 71 and 72 are pivotally attached to base plate 62 by pivot pins 74 and 76 respectively such that links 71 and 72 are free to rotate in a plane parallel to the plane of base plate 62 . Pivotally attached to the opposite ends of diagonal links 71 and 72 are vertical links 78 and 79 as illustrated in FIG. 6. Thus links 71 , 72 , 78 , and 79 form a movable parallelogram whereby the theoretical area, therein, may be expanded and/or collapsed. Link 79 is provided a cam follower, or roller, 77 projecting into the plane of rotation of links 71 and 72 .. Similarly vertical link 78 includes pin 73 extending into the plane of rotation of links 71 and 72 .
[0030] Cam wheel 60 is pivotally attached to base plate 62 by pivot pin 54 whereby cam link 60 is free to rotate within the plane of links 71 and 72 between base plate 62 and vertical links 78 and 79 as illustrated in FIGS. 9 and 10. Cam wheel 60 has two cam surfaces 63 and 64 . Both cam surfaces 63 and 64 are of a circular configuration concentric about pivot 54 with surface 64 being of a larger radius than surface 63 . A camming ramp, or step, 66 acts as a transition from surface 63 to surface 64 . Extending radially outward from cam surface 63 is arm 61 . The function of cam surfaces 63 and 64 , ramp 66 , and arm 61 will be described more fully below.
[0031] When car doors 12 and 13 are in there respective closed position, as illustrated in FIG. 2, all elements of clutch assembly 18 , on car door 13 , are positioned as shown in FIGS. 5 and 6. Cam arm 61 is in engagement with pin 73 on vertical link 78 thereby preventing tension spring 65 from collapsing the collapsible parallelogram formed by links 71 , 72 , 78 , and 79 . Cam follower 77 , on vertical link 79 , is in engagement with, or slightly removed from cam surface 63 and immediately adjacent to ramp 66 between cam surfaces 63 and 64 .
[0032] As car door 13 begins to open, by virtue of the horizontal force applied by link 22 through cam wheel 60 and pivot 54 , cam wheel 60 begins to rotate clockwise on door 13 (counterclockwise on door 12 ) see FIG. 2. As cam wheel 60 rotates clockwise, cam arm 61 rises releasing its hold on pin 73 and ramp 66 engages cam follower 77 , on vertical link 79 , and with the assistance of tension spring 65 , forces vertical link 79 downward and vertical link 78 upward thereby causing vertical links 78 and 79 to move laterally toward one another by action of the collapsing parallelogram formed by links 71 , 72 , 78 , and 79 .
[0033] Referring now to FIGS. 1, 8 and 11 . If elevator car 10 is in a landing zone, or safely close to a landing, door unlocking and opening rollers 26 and 27 , of roller coupling assembly 21 , will be positioned between vertical links 78 and 79 of clutch assembly 18 as illustrated. As shown in FIG. 11, rollers 26 and 27 are typically positioned side by side with roller 26 rigidly affixed to assembly 21 while roller 27 is permitted to move laterally approximately one quarter of an inch. When coupling assembly 21 is positioned between vertical links 78 and 79 each roller, 26 and 27 , is typically provided approximately one quarter of an inch clearance between roller surface and vertical links 78 and 79 respectively. Thus when the collapsing parallelogram formed by links 71 , 72 , 78 , and 79 closes upon rollers 26 and 27 vertical link 79 need only translate one quarter of an inch to engage roller 26 however, vertical link 78 must not only translate one quarter of an inch to engage roller 27 but it must also translate an additional quarter of an inch pushing roller 27 to its lateral stop to firmly grip coupling assembly 21 . Therefore, in order to provide the additional travel required by vertical link 78 lateral links 71 and 72 are eccentrically pivoted about pivots 74 and 76 respectively, whereby link 78 will move faster and laterally further than link 79 by virtue of the longer pivot radius about pivots 74 and 76 .
[0034] As roller 27 is pushed toward roller 26 by vertical link 79 door unlatching link 30 is caused to move vertically thereby unlatching door locking lever 34 permitting the door to open.
[0035] When elevator car doors 12 and 13 close, by action of power drive 40 , cam wheel 60 , on door 13 , will rotate counterclockwise, as viewed in FIGS. 5 and 6, whereby cam arm 61 will engage pin 73 , on vertical link 78 , and by overcoming the force of tension spring 65 force vertical link 78 downward causing vertical links 78 and 79 to separate releasing their grip upon door opening rollers 26 and 27 and thereby returning clutch assembly 18 to its closed door configuration permitting elevator car 10 to move on to another landing. Roller 27 being pivotally biased to separate from roller 26 , because of the weight of link 30 upon lever arm 36 , will separate from roller 26 thereby causing the landing door locking lever 34 to engage and lock the landing door from being forced open.
[0036] In the event Elevator car 10 stops outside a landing zone, for example as a result of a power failure, elevator car doors 12 and 13 might be pushed open by passengers inside the car by overcoming the resisting torque of power drive assembly 40 . However, it is desirable that car doors 12 and 13 be pushed open only to a given position to permit air ventilation within the car. Clutch 18 further acts to limit the car door opening as described in greater detail below.
[0037] [0037]FIG. 5 illustrates an optional feature that may be added to the present invention. Attached to a door suspension assembly 32 of car door 13 by pivot 58 is latching arm 56 . Latching arm 56 is connected to vertical link 78 of clutch assembly 18 by link 52 as illustrated.
[0038] Referring additionally to FIGS. 5A, 5B, and 5 C. If car 10 stops outside a landing zone, rollers 26 and 27 , of landing door coupling assembly 21 , will not be positioned between vertical links 78 and 79 of clutch assembly 18 . Thus if car doors 12 and 13 are forced open, clutch assembly 18 will function as described above whereby cam wheel 60 will rotate clockwise, by action of links 22 and 20 , and actuating arm 48 of power drive assembly 40 whereby arm 61 of cam wheel 60 will rotate clockwise and upward, as viewed in FIGS. 5 and 6, thereby releasing its hold upon pin 73 . Vertical links 78 and 79 , now being unrestricted, and being drawn together by action of tension spring 65 may close more fully than when roller coupling assembly 21 is therebetween.
[0039] Upon collapse of the parallelogram formed by links 71 , 72 , 78 , and 79 , vertical link 78 is permitted to move further upward than it would if a landing door coupling assembly 21 was therebetween, thereby, similarly, forcing latching link 52 further upward causing latch 56 to rotate counterclockwise about pivot 58 . As door 13 moves further, latching link 56 progressively rotates downward, as illustrated in FIGS. 5A, 5B, and 5 C until latch 56 travels over center, as illustrated in FIG. 5C, whereby latch 56 will engage bracket 57 attached to door rail 59 thereby preventing further opening of door 13 .
[0040] Preferably vertical links 78 and 79 also includes roller engaging plates 68 and 69 , respectively, having diverging end flanges as illustrated in the figures. The diverging end flanges, of plates 68 and 69 serve to guide rollers 26 and 27 , of roller coupling assembly 21 , there between, see FIGS. 8 and 11, when the elevator car is reengaging the hoistway rollers 26 and 27 after manual disengagement for maintenance purposes.
[0041] Although the preferred embodiment as disclosed herein teaches an elevator having two car doors with two associated landing doors wherein a separate clutch assembly is included for each car door, the clutch assembly as described and claimed herein may also be effectively used on an elevator car having a single car door with a single associated landing door. Further the clutch assembly, as taught and claimed herein, may be used on an elevator car having two car doors wherein a single clutch assembly is positioned on one “master” door and the second car door is “slaved” to the master door and operated by means such as cables, gears or mechanical linkages.
[0042] It should be further understood, by those skilled in the art, that various other changes, modifications, omissions and/or additions in form and detail of the preferred embodiment taught herein may be made therein without departing from the spirit and scope of the claimed invention. | An elevator car door opening and closing apparatus is taught having a clutch assembly carried by each car door for coupling with a landing door locking and unlocking assembly whereby the car and landing doors open and close simultaneously. The clutch assembly includes a mechanical expanding and collapsing parallelogram mechanism which engages, unlocks, and opens the landing door. Mechanical means is also disclosed whereby the elevator car doors may only be forced opened a limited amount if the car is stalled between landing sites. | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a divisional application of U.S. patent application Ser. No. 10/503,168, filed Jul. 30, 2004, issued Feb. 24, 2009, as U.S. Pat. No. 7,494,769, which is a 371 of PCT/US03/11723 filed Apr. 16, 2003, which claims the benefit of U.S. Provisional Application Ser. No. 60/373,080, filed on Apr. 16, 2002, the contents of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention generally relates to a sampling methodology. PMore particularly, the present invention is directed to a method and apparatus utilizing a luminescence spectroscopy to detect bioaerosols and alert of the presence of a potentially pathogenic bioaerosol.
2. Description of the Related Art
Aerosols of biological origin, whether formed intentionally or unintentionally, represent a potential threat of infection by pathogens. This threat is particularly daunting in the context of closed spaces, such as buildings. A variety of methods directed to identifying harmful biological materials are known. One of the known methods is based on the principles of the luminescence spectroscopy and is concerned with the production, measurement, and interpretation of electromagnetic spectra arising from either emission or absorption of radiant energy by various substances.
One aspect of the luminescence spectroscopy provides for the ability of biological materials to fluoresce due to the presence of proteins that possess certain amino acids. Fluorescence occurs when fluorophores and fluorescent particles absorb light at a given wavelength and then immediately emit light at a longer wavelength. Although not all particles fluoresce, some bio-aerosols contain intrinsic fluorophores that could potentially be used to tag the sample as a bioaerosol. Common fluorophores found in bioaerosol are, for example, Nicotinamide Adenine Dinucleotide (NADH), Tryptophan, Tyrosine, and Riboflavin. Each of these flurophores is characterized by respective peak excitation and corresponding emission wavelengths.
The primary fluorescent amino acids are tyrosine and tryptophan. The latter compound absorbs and emits at longer wavelengths and is less likely to have spectral overlaps with compounds that are not of a biological origin. However, there are still many environmental elements and hydrocarbons that will also fluoresce in the same wavelength as tryptophan, let alone the rest of the above-mentioned fluorophores.
Another aspect of the luminescence spectroscopy that may provide a tool for detecting biological materials is phosphorescence. As compared to fluorescence, phosphorescence is characterized by the time delay emission signal that allows for time-resolution to be used as a discriminator between samples that fluoresce versus those that phosphoresce. Hence, it is possible to delay the detection of the signal until after the light source has been extinguished and the fluorescent signal has disappeared. In addition to the time delay, Tryptophan phosphoresces at a longer emission wavelength.
Most of the known biological detectors incorporate fluorescence as a means for detecting the presence of a biological aerosol. Although fluorescence is a relatively simple approach, its major disadvantage, as discussed above, is the low selectivity for the bioaerosols of interest.
Current biological aerosol detection/triggering technology including the Biological Aerosol Warning Sensor (BAWS) developed by the Massachusetts Institute of Technology and the ultra Violet Aerodynamic Particle Sizer (UVAPS) developed by TSI is acceptable. However, these instruments are expensive, power hungry, large, and require complex algorithms to determine relatively little information.
A need, therefore, exists for a methodology either perfecting or complementing a fluorescence detection technique and for an inexpensive, low power, robust apparatus carrying out the inventive methodology.
Thus, one of the objects of the present invention is to provide a method for detecting pathogenic bioaerosols having a secondary detection technique to complement fluorescence.
Another object of the present invention is to provide an apparatus for carrying out the inventive method and capable of effectively collecting bioaerosols and selectively detecting the presence of the biological materials of interest contained in the bioaerosols.
Still another object of the present invention is to provide the inventive apparatus adapted to generate a warning upon detecting the biological materials of interest and to trigger secondary, more sophisticated, equipment for the confirmation of the initially detected materials and their further identification.
A further object of the present invention is to provide the inventive apparatus characterized by a simple, space- and cost-efficient structure.
Yet another object of the invention is to provide a detection system including multiple inventive apparatuses and deployed in a single location to provide added discrimination of actual threat levels.
SUMMARY OF THE INVENTION
These and other objects have been achieved by a new method, characterized by the collection of bioaerosols and further excitation of a sample thereof to controllably discriminate between biomaterials that fluoresce versus those that phosphoresce. The latter would indicate the probability of the presence of biological materials of interest in the excited sample.
The inventive method utilizes both fluorescence vs. fluorescence-based detection as well as fluorescence vs. phosphorescence-based detection. The optical system of the inventive sensor includes two optical channels both operative to detect fluorescence signals emitted at different wavelengths and associated with different bioagents. However, in addition to exclusively detecting fluorescence, one of the optical channels is also configured to detect phosphorescence after the detection of the fluorescence has been completed.
In the case of fluorescence vs. phosphorescence, if the former is detected by one of the optical channels, the possibility of the presence of a biomaterial of interest exists. Subsequent detection of the phosphorescence during the second stage indicates the probability of the presence of the biomaterial of interest. Since the inherent advantage of phosphorescence over fluorescence is the time delayed emission signal, the inventive apparatus is operative to allow for time-resolution to be used as a discriminator between samples that fluoresce versus those that phosphoresce. As a result, the two-stage inventive method maximizes the probability of detection and minimizes the number of false alarms.
In accordance with another aspect of the inventive method, a heavy atom perturber that has chemical affinity for association with the molecules, whose phosphorescence is desired, is bonded with the sampled material. As a consequence, if a biological agent to be detected is present in the sampled material, phosphorescence occurs at a known wavelength.
A further aspect of the present invention provides for an apparatus operative to carry out the inventive method. The inventive apparatus includes mechanical, optical, and electronic sub-systems controllably cooperating with one another to collect a sample of bioaerosol, optically excite it and electronically process emitted signals to detect the presence of the biomaterials of interest.
One of the advantages of the inventive apparatus is based on the characteristic of the phosphorescence to emit light waves at wavelengths after a light source has been extinguished. By configuring a two-channel optical system and providing an electronic processing unit with software, which executes on the processing unit, the desired sequence of mechanical, optical and electronic operations leading to the minimization of false alarms and the maximization of detection is established and maintained. This, of course, does not eliminate the possibility of simultaneously detecting different fluorescence intensities by both optical channels, only one of which is configured to detect phosphorescence in addition to the ability to detect fluorescence.
In accordance with a further aspect of the present invention, phosphorescence of the biomaterials of interest at room temperature is induced by controllably adding a heavy atom perturber to the sample in the presence of an oxygen scavenger. The latter is used to minimize the possibility of the fluorescence of non-biological materials. As a result, the apparatus can indicate the presence of the biomaterial of interest based on its phosphorescence without, however eliminating the detection of this material based on its fluorescence.
While the inventive apparatus can be used for a variety of purposes, desirably it can be associated with a plurality of identical apparatuses or sensors to provide a network operative to alert building, office and/or industrial site occupants of the presence of a potentially pathogenic bioaerosol. Simplicity of the inventive structure and its space-efficient configuration can be used to construct a warning system capable of generating a real time detection/information about bioagents of interest and of triggering a more sophisticated system to confirm and identify these bioagents.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other objects, features and advantages will become more readily apparent from the following detailed description accompanied by the drawings, in which:
FIG. 1 is a flow chart illustrating an inventive method for detecting bio-aerosols;
FIG. 2 is a perspective simplified view of an apparatus carrying out the inventive method of FIG. 2 ;
FIG. 3 is a schematic diagram of the fluidics and electro-optics systems of the inventive apparatus shown in FIG. 2 ;
FIG. 4 is a simplified perspective view of the optic system shown in FIG. 3 ;
FIG. 5 is a flow chart illustrating the operation of the processor of the electronic system diagrammatically illustrated in FIG. 4 ; and
FIG. 6 is a schematic diagram of a warning system installable in a building.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 illustrates an inventive method 10 based on the realization that hazardous biological materials dispersed in a particulate-containing airstream emit phosphoresce radiation at room temperature if bonded with an external heavy atom perturber (EHAP) in the presence of an oxygen scavenger, e.g., sodium sulfite.
In accordance with the above-stated inventive concept, the method 10 provides for the collection of a bioaerosol sample, as indicate by step 12 . Following the collection of the bioaerosol sample, the latter is mixed with an EHAP. Among EHAPs for use herein, include, for example, one or more of potassium iodide, lead, thallium, lutetium, gallium, cesium, and barium each of which advantageously have a sufficient chemical affinity for association with the molecule of fluorophores contained in an airstream. Common fluorophores found in aerosols that can potentially be used to tag the collected aerosol sample are, for example, NADH, Tryptophan, Tyrosine, Riboflavin and the like. For example, if Tryptophan is complexed with an EHAP, as indicated by step 14 of FIG. 1 , it will phosphoresce when excited at a predetermined excitation wavelength, as shown by step 16 . To provide distinct phosphorescence, it is desirable to reduce the fluorescent radiation generated by the materials of interest at a shorter wavelength by mixing the sample of bioaerosol with an EHAP in the presence of the oxygen scavenger. Ox
However, the fluorescence radiation can be indicative of biological materials of interest and neglecting a fluorescent signal may lead to catastrophic results. As a consequence, the inventive method 10 provides for the detection of fluorescence, as an initial detection technique, as shown by step 18 of FIG. 1 . Moreover, the inventive method can be utilized to provide for simultaneous detection of two or more fluorescence signals having different intensities, each of which may be associated with a respective bioagent contained in the collected bioaerosol.
Criticality of phosphorescence versus fluorescence in the context of the method 10 is the time delayed emission signal associated with the former and allowing for time-resolution to be used as a discriminator between the detected biomaterials that fluoresce against those that phosphoresce. The time delay is an advantage because it is possible to delay the detection of the signal until after the light source has been extinguished, as will be explained in detail below. Another critical characteristic associated with phosphorescence when compared with fluorescence is the different wavelengths of the emitted signals. For example, when excited with 285 nm light, Tryptophan will fluoresce at 360 nm, but it will phosphoresce at 450 nm. The above-identified differences are important to the inventive method providing for extinguishing an excitation source during step 20 to finally determine the probability of the presence of biological agents or biomaterials of interest if a phosphorescent signal is detected during step 22 . Accordingly, the inventive method advantageously employs a two-stage fluorescence/phosphorescence detection technique allowing for a sequential identification of bio-materials of interest. Also, the inventive method allows for detection of two fluorescent signals associated with different wavelengths and intensities, which can be indicative of different fluorophores.
Turning now to FIGS. 2-5 , a sensor 30 is able to detect bioaerosols based on a dual channel luminescence detection technique in accordance with the inventive method. The sensor 30 is a compact device having dimensions, which are approximately 12″×16″×8″. In addition, as will become clear from the following description, the sensor 30 has a simple and cost efficient structure allowing, thus, the sensor to be placed in large quantities in a building to alert building occupants of potentially dangerous biomaterials contained in air.
As shown in FIG. 2 , the sensor 30 comprises three primary units including at least a mechanical system, an optical system and an electronic system. The mechanical system is configured to collect a sample and transport the latter to the optical system operative to excite, emit and detect emission signals having wavelengths of interest. The electronic system is adapted to process the emissions signals and control the desired sequence of operations established to carry out the inventive method 10 . These systems of the sensor 30 are packaged in a housing 24 made from a material capable of withstanding mechanical loads to preserve the functionality of the entire system even under adverse conditions.
The mechanical system includes at least a particle sampler or collector/concentrator as generally indicated as 34 ( FIG. 2 ) and operative to rapidly provide the sample in a form that can be processed by the optical system. There are several issues that make sampling for biological agents particularly challenging. The first issue is that the sampling is normally targeted at living organisms; therefore, the technology must not “harm” the sample. Secondly, the target bio-material is generally only one component of a complex matrix of biological elements and chemical compounds that may affect the detection process, so the sample must often be purified to some extent. Lastly, the sample must be highly concentrated for a rapid analysis. An air-liquid surface virtual and/or real concentrator and/or an air-solid surface concentrator can readily deal with all of the above-discussed issues within the scope of the invention. As the names indicate, the former provides for the impingement of airborne particulates upon a reservoir filled with liquid, whereas the latter features a solid surface such as a bare or coated with mineral oil vacuum grease tape, paper, metal or any other suitable solid surface. Both types of the impactors are utilized within the scope of the present invention, as will become more readily apparent from the following description. In practical terms, a sampling stage is initiated upon actuation of a vacuum pump directing an airstream 36 ( FIG. 3 ) through the concentrator into a sample vessel or collector 38 ( FIG. 3 ), which is located downstream from the impactor. Depending on the particular test, a sample collector 38 can be configured to have a fluid reservoir or a solid surface both serving as a particle impinging and collecting concentrator.
If the collector 38 features a liquid surface, the mechanical system is provided with a sample of a fluid reservoir 44 ( FIGS. 2 and 3 ), which is in fluid communication with the collector. Particularly, a fluidic control scheme includes a controllable first pinch valve 31 opening in response to a signal generated by the electronic system and simultaneously with actuation of a peristaltic pump 32 . As a result, buffered water from the reservoir 44 is first pumped into the collector 38 , which, in this case, is an impinger type of aerosol to liquid collector. After the aerosol has been collected, the liquid sample is delivered through another controllable pinch valve 31 to an optical cell 50 , which can be associated with either a flow through cuvette or a closed cuvette ( FIG. 3 ).
In accordance with one aspect of the inventive concept provided for detection of fluorescence and phosphorescence, as the sample is transported towards the cell 50 , it is mixed with chemicals, i.e., the heavy atom perturber and oxygen scavenger. Particularly, the sample is bonded with the EHAP stored in a chemical reservoir 46 ( FIG. 2 ) and controllably delivered into a sample path upon actuation of another peristaltic pump 32 . Note that various types of pumps and valves are contemplated with the scope of invention and subject only to local objectives and experimentation.
Alternatively, if the collector 38 is configured as an aerosol to solid surface concentrator, a mechanical means, which among others can include a simple robotic arm (not shown), delivers the concentrated sample to the cell 50 . While transporting the sample, it is mixed with the EHAP and the oxygen scavenger to induce phosphorescence light associated with any biomaterial of interest, provided, of course, that the material is present in the sample.
Having delivered the sample mixed with the EHAP to the optical cell 50 , the optical system, illustrated generally as 26 in FIG. 2 , provides an optical analysis of the delivered sample by causing the sample to induce fluorescence and phosphorescence light signals and convert them into electrical signals. The optical system is configured to excite the sample by initially turning a light source, such as a Xenon flash lamp 52 ( FIGS. 3 and 4 ), which generates discontinuous pulses of light incident upon the sample. As a result, if the biomaterial of interest is present, the sample emits fluorescent and possibly phosphorescent lights propagating along two optical channels, each of which includes a photo multiplier tubes (PMT) 56 , 58 ( FIGS. 3 and 4 ) amplifying signals emitted at selective frequencies.
To analyze the specimens constituting the sample, the current level applied to the lamp 52 causes the latter to emit optical energy in the ultraviolet range. To reduce the amount of dispersion, the output from lamp 52 is processed by a filter 54 , so that the sample is only excited by a predetermined wavelength varying within the UV range; the filtered output is eventually focused on the cell 50 by means of an upstream lens assembly 60 . To boost the signal amplitude at the integrator output, the lamp 52 preferably generates three pulses fired in rapid succession at about 25 ms intervals.
Assuming that the sample contains the bio-materials of interest capable of emitting at least fluorescent light, two optical channels of the optical system are configured to selectively pass and amplify fluorescent signals propagating at different frequencies. Based on experimentation data, the 450 nm PMT 58 optically coupled with an outlet of the first optical sub-system, which includes a filter 62 and focusing lens systems 60 , generates an amplified electrical signal in response to detection fluorescence of NADH. The other optical channel includes the 360 nm PMT 56 coupled to a second optical sub-system, which is configured similarly to the first one, and used to primarily detect fluorescence. In addition, the 450 nm PMT is also capable of detecting phosphorescence of Tryptophan upon extinguishing the lamp 52 for a predetermined period of time.
It has to be noticed that all distances, including that between the optical cell 50 and the PMTs 56 , 58 , the optical cell and the lamp 52 , have to be experimentally optimized to allow for maximum light transmission through the system. A few optional modifications of the overall optical system can include, for example, a gated PMT 59 ( FIG. 3 ) that can be added to the 450PMT in order to control the time delay activation of the photo multiplier tube and to prevent the saturation of the phosphorescence measurement by the fluorescent signal. Another potential contribution to the saturation issue is the proper selection of the filter 62 coupled to the 450PMT; it is desirable that a filter rated at optical density (OD) 5 with about a 10 nm bandwidth be installed. The relatively high OD provides more efficient blocking of light emissions that are not within the bandwidth of interest. Note that all dimensions, ranges and numeric characteristics are subject to numerous variations, which primarily depend from the type of bio-agents to be detected.
Assuming that either two fluorescence signals have been simultaneously emitted or the fluorescence and phosphorescence light signals have been sequentially emitted, the output electrical signals of the PMTs 56 , 58 are received by the electronic system 70 ( FIGS. 3 and 5 ). The electronic system is configured to process electrical signals outputted by the PMTs 56 , 58 via connectors 64 ( FIG. 3 ) into amplifier circuits of a controller card 28 ( FIG. 2 ) and to compare the processed signals with respective reference values. The desired sequence of actuation of pumps, valves and other components as well as automatic triggering of the more sophisticated equipment are likewise controlled by the electronic system 70 .
The heart of the electronic system 70 is a processor having software executed thereon for sequentially operating the sensor 30 in a manner consistent with the inventive method 10 . As is typical for the rest of the disclosed components, among a variety of suitable devices, a MC68HC11, which is an 8-bit processor chip, and three amplifier circuits control system timing and overall signal processing.
As better illustrated in FIG. 5 , software executed on the processor initially actuates the mechanical system. A particular sequence of pump and valve operations depends on whether the collector 38 has an air-liquid or air-solid surface configuration. If the air-liquid surface type is incorporated in the sensor 30 , initially the peristaltic pump 32 and the first pinch valve 31 are actuated in a rate- and time controlled manner to allow for the passage of liquid into the sample vessel, as indicated by a step 90 . Subsequently, the vacuum pump responsible for drawing the aerosol 36 ( FIG. 3 ) into the sample vessel is turned on to sample and collect biomaterials of interest, as indicated by a step 92 . Further transportation of the concentrated sample to the optical system, is associated with the controlled actuation of the downstream pump 32 and the second valve 31 openable to provide mixing of the sample with the EHAP and the oxygen scavenger, as indicated by step 94 . The latter is necessary if the sensor 30 is used to detect not only fluorescence, but phosphorescence as well.
Alternatively, if the concentrator 38 has a solid surface, the aerosol is initially forced along an impactor means at 72 to accumulate on the solid surface where the sample is mixed with the EHAP and O 2 scavenger injected, as shown by step 94 , either directly onto the surface. Alternatively, the EHAP and O 2 scavenger can be added as the concentrated sample is transported, as shown by step 74 , towards the photocell 50 .
Upon delivery of the sample to the optical cell 50 , the lamp 52 is energized in a controlled pulsed manner, as shown at 76 , and if the biomaterials of interest are present in the sample, they produce a signal detected and magnified by the PMT 56 . A comparator of the electronic system 70 compares the received signal with a first threshold, as shown by step 78 , and if the intensity of this signal is lower than the first threshold, the mechanical system is re-activated to evacuate the sample to a sample waste reservoir 80 . Note, if the sensor 30 operates only in a fluorescence vs. fluorescence mode, both PMTs 56 and 58 detect respective fluorescent signals simultaneously. Both signals propagating at different wavelength and having different intensity are compared with respective reference or threshold values. For example, the optical channel provided with the PMT 56 is operative to detect fluorescence emissions in the 360 nm-wavelength band which is associated with tryptophan and bioaerosols containing this flurophore. The other channel including the PMT 58 is operative to detect fluorescence emissions in the 450 nm-wavelength band associated with NADH and bioaerosols containing the latter.
If, however, the sensor 30 in a fluorescence vs. phosphorescence mode, the signal detected after the lamp 52 has been extinguished at 82 by the PMI 58 corresponds to a phosphorescent signal. This signal can be associated with Tryptophan phosphorescence. Similarly to the first mode of operation, in the second mode of operation, both signals—fluorescence and phosphorescence—are sequentially compared to respective thresholds. If the phosphorescence signal passes the master, as indicated by step 84 , the sample is conveyed to a sample reservoir 86 where it is stored for further examination. However, even if the phosphorescence master is not passed in the second mode, the sample is still saved in the sample reservoir 86 for further detection, since it certainly contains a material, which can be of a biological origin capable of fluorescing, as determined at 78 . The latter procedure is also applicable to the first mode operation, wherein as either of the two fluorescence signals at least matches a respective threshold, the sample is rerouted to the sample reservoir 86 for further detection.
Software executed on the processor, can trigger the more sophisticated detection system, as shown by step 88 , which, in turn, is coupled to the sample reservoir 86 to further evaluate the stored sample. Furthermore, an audible signal generated by a piezoelectric or other type buzzer 98 and a visual signal 100 can be generated either immediately upon detecting the biomaterial of interest.
As shown in FIG. 6 , it is contemplated to assemble a plurality of the sensors 30 and strategically placed them in a building or in any other “closed” space structure equipped with a central processor 102 . The central processor will be able to receive a signal generated by any of the sensors 30 and identify the location of the triggered sensor. The central processor 102 can trigger the more sophisticated detection equipment 96 configured to continue the examination of the stored sample and characterized by higher sensitivity and selectivity capabilities.
Further modification of the sensor 30 may include, for example, the installation of a control panel coupled to the electronic system 70 and operative to allow the operator to manipulate variable parameters including, but not limited to the timing of the pumps for the fluidic system, the reference (alarm) threshold values, the collection time, the duration of on-state of the lamp and many others. There is an opportunity to improve the selectivity of the sensor 30 by including phosphorescence measurements or adding a particle counter. It should be understood that the inventive sensor can operate on a cyclical basis.
While the invention has been shown and described with references to certain preferred embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the invention as defined by the appended claims. | A method and apparatus for evaluating a bioaerosol sample is provided which includes detecting frequency and/or time resolution factors that allow discriminate between a plurality of signals emitted by the bioaerosol to selectively detect biological materials contained in the bioaerosol sample from materials of non-biological origin and potentially associated with a pathogenic bioaerosol. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of International Patent Application No. PCT/EP2009/008226, filed Nov. 19, 2009, which claims the benefit and priority of EP 08022458.7, filed Dec. 24, 2008. The entire disclosures of the above applications are incorporated herein by reference.
BACKGROUND
The invention relates to a system for inserting a sensor for measuring an analyte, e.g., glucose, under in vivo conditions, and a corresponding insertion device.
In order to insert sensors for measuring analyte concentrations under in-vivo conditions, for example, glucose concentrations, in body tissue of a patient, for example, in subcutaneous fatty tissue, it is customary to use insertion devices that effect a puncturing motion of an insertion needle by means of a drive mechanism. Customary insertion needles for this purpose are designed as hollow needles or V-shaped trough, in which a sensor is situated. The sensor can, for example, be provided as an electrode system for electrochemical measurements or comprise a micro-fluidic catheter for guiding a perfusion fluid in and out. After a puncture is made, the insertion needle is retracted from the body tissue, whereby the sensor remains in the puncturing wound thus generated.
Another application of insertion devices is, for example, the application of catheters, in particular for infusion of insulin or other active substances.
Combined with a base unit to which they can be coupled for an insertion, insertion devices of this type form an insertion system. It is customary to glue base units to the body of a patient. Subsequently, an insertion device can be coupled to the base unit. After the insertion is completed, the insertion device can be un-coupled from the base unit such that the base unit remains on the body of the patient, for example, as carrier or connection element of an inserted sensor or catheter.
Insertion systems are often operated by the patients themselves, for example, in order to insert catheters for connection to an insulin pump or sensors for measuring the glucose concentration. Therefore, it is a steady aim in the development of such insertion systems that they can be operated as easily and safely as feasible.
This object is met by an insertion system and insertion device having the features described herein.
SUMMARY
According to the invention, the insertion device includes a locking mechanism which, in an active state, effects locking of the drive mechanism and is transitioned to an inactive state, in which the locking is released, by coupling the insertion device to the base unit. A locking mechanism of this type, which locks the drive mechanism in its active state, can be used to prevent premature triggering of a puncture and thus reduce the risk of injury while handling the insertion device.
In an insertion device according to the invention, the locking mechanism unlocks automatically upon coupling of the insertion device to the base unit. Accordingly, what can be attained according to the invention is that the locking mechanism is unlocked only when the insertion device is coupled to the base unit. What can therefore be advantageously attained is that a user can unlock the locking mechanism only by coupling the insertion device to the base unit. Advantageously, a puncturing can therefore be triggered only when the insertion device is coupled to the base unit such that the risk of injury due to incorrect handling is largely excluded.
Aside from increased safety from injuries, another advantage of the locking mechanism according to the invention is that the operation of the insertion device can be simplified significantly. Whereas known insertion devices usually use more or less laborious and complicated triggering or actuation mechanisms to prevent inadvertent triggering of a puncture, for example, by means of providing multiple actuation elements that need to be actuated in a given order or combination, measures of this type are dispensable in the insertion system according to the invention. Since the drive mechanism can effect a puncture only after coupling of the insertion device to the base unit, premature triggering of a puncture is excluded even upon the use of the simplest triggering and actuation mechanisms.
A securing mechanism according to the invention can, for example, be transitioned from its active state to its inactive state by means of magnetic force. Magnets required for this purpose can be attached to the base unit and/or the insertion device. It is feasible just as well to deactivate the securing mechanism by electrical means by closing an electrical contact while coupling the insertion device to the base unit. However, it is preferable for the securing mechanism to operate by purely mechanical means, for example, by providing on the base unit an index pin that actuates the securing mechanism during the coupling process and thus transitions it to the inactive state.
A locking mechanism according to the invention can, for example, operate with a safety catch, a rocker or a similar locking element that is transitioned from a locked state to an inactive state by means of a rotating or swinging motion. However, it is preferable for the locking mechanism to include a slider that is displaced during a switch of the locking mechanism from the active state to the inactive state. A slider of this type can, for example, carry a locking element that blocks the drive mechanism, in particular by means of a positive fit-type engagement.
It is also feasible for the slider, which is preferably present in a locking mechanism according to the invention, to itself lock the drive mechanism as a locking element by means of form-fitting engagement in the drive mechanism or in an actuation element that can be actuated by a user. Basically, a slider of this type might be displaced in an arbitrary direction upon a switch of the locking mechanism from the active state to the inactive state. However, preferably, the slider can be displaced in the puncturing direction since this facilitates a compact design.
An advantageous refinement of the invention provides the slider to be subjected to the action of a spring. In this context, any component that generates a restoring force upon deformation can be used as spring. For example, a plastic block capable of elastic deformation, a coil made of plastic or metal, and a band capable of elastic deformation, for example, a rubber band, can be used as spring. What can be attained by means of the use of a slider subjected to the action of a spring is that said slider is moved to a starting or final position by means of spring force. Accordingly, the risk of the slider remaining in an undefined intermediary state between the starting and the final position for extended periods of time can, therefore, be reduced. Preferably, the spring relaxes when the locking mechanism switches to the inactive state, i.e., releases at least a fraction of the energy that is stored in it. This measure is advantageous in that a user does not need to expend additional force for deactivation of the locking mechanism. Moreover, a particularly simple design of the locking mechanism can be attained in this manner, since it suffices to block any displacement of the slider in the active state of the locking mechanism by means of a mobile element, for example, a limit stop or barrier. Upon coupling the insertion device to a base unit, an element of this type can be moved by means of contact to a matching component of the base unit and a displacement of the slider can thus be facilitated.
Preferably, the slider is coupled to a latching element that is slid into an engagement position when the insertion device is coupled to the base unit, in which engagement position it connects the insertion device to the base unit in a positive fit-type manner. What can be attained in this manner is that the locking mechanism transitions to its inactive state only once the insertion device is connected to the base unit in a positive fit-type, and therefore reliable, manner.
Preferably, the locking mechanism includes a protection element which, in the active state of the locking mechanism, is situated in front (in the direction of puncturing) of an insertion needle that is held by the insertion needle holder. This measure is advantageous in that the insertion needle is covered and thus the risk of injury during any handling of the insertion device is further reduced. A protection element of this type can, for example, be connected to the above-mentioned slider, in particular connected by a joint, such that it is pushed aside during transition of the locking mechanism to the inactivate state such that the path for a puncturing motion of the insertion needle is thus freed. The protection element, which can, for example, be provided to be plate-shaped, can advantageously be connected to the above-mentioned latching element, in particular provided as a single part that also includes the latching element, which effects a positive fit with the base unit when the insertion device is coupled.
The drive mechanism of an insertion device according to the invention can contain an energy storage device, for example, a spring, in order to supply the energy required for a puncturing motion. However, it is also feasible for the drive mechanism of the insertion device according to the invention, in operation, to convert a drive motion of an actuating element into a puncturing motion of the insertion needle holder. In this context, it is preferred for the drive mechanism to effect a returning motion of the insertion needle holder subsequent to a puncturing motion, and to be blocked after the returning motion is completed. Said blockade can be effected by the locking mechanism also or by a mechanism that is independent thereof. It is feasible, for example, that an actuating element whose drive motion is converted into a puncturing motion by the drive mechanism to snap into place at the end of its actuation path.
DRAWINGS
Further details and advantages of the invention are described by means of exemplary embodiments making reference to the appended drawings. In this context, identical and corresponding components are labeled with consistent reference numbers.
FIG. 1 shows an embodiment of an insertion device according to the invention;
FIG. 2 shows an embodiment of a corresponding base unit;
FIG. 3 shows a detail of the insertion device shown in FIG. 1 with its housing being open;
FIG. 4 shows a view according to FIG. 3 with the base unit being coupled;
FIG. 5 shows a detail of another embodiment of an insertion device with its housing being open; and
FIG. 6 shows a view according to FIG. 5 with base unit coupled.
DETAILED DESCRIPTION
The following description of technology is merely exemplary in nature of the subject matter, manufacture and use of one or more inventions, and is not intended to limit the scope, application, or uses of any specific invention claimed in this application or in such other applications as may be filed claiming priority to this application, or patents issuing therefrom.
The insertion device 1 shown in FIG. 1 and the base unit 2 shown in FIG. 2 jointly form an insertion system that can be used, for example, to insert sensors by means of insertion needles or catheters for the infusion of insulin or other active substances into the body of a patient. For insertion, the bottom side of the base unit 2 is glued to the body of a patient and then the insertion device 1 is coupled to the base unit 2 .
The insertion device 1 shown in FIG. 1 has two actuating elements 3 , which are moved towards each other in a drive motion for an insertion. Said drive motion is converted into a puncturing motion of an insertion needle holder and thus of an insertion needle by a drive mechanism that is shown in FIGS. 3 to 6 .
As shown in FIG. 3 , the actuating elements 3 are provided with toothed racks 4 , which cause a rotor 5 to rotate when the two actuating elements 3 are squeezed together, whereby the rotation is converted via a connecting rod 6 into a linear puncturing motion of an insertion needle holder 7 and of an insertion needle 8 carried by the holder. The toothed racks 4 , the rotor 5 , and the connecting rod 6 jointly form the drive mechanism of the insertion device 1 .
In order to counteract a risk of injury due to a premature puncturing motion, the insertion device 1 has a locking mechanism 10 , which, in an active state, effects a locking of the drive mechanism, i.e., blocks its motion, and is transitioned to an inactive state, in which the locking is released, by coupling the insertion device 1 to the base unit 2 .
In the embodiment shown in FIG. 3 , the locking mechanism 10 includes a slider 11 that carries a locking element 12 , which, in the active state shown in FIG. 3 , engages a recess 13 of one of the actuating elements 3 and thus blocks the drive mechanism. The slider 11 is connected by a joint by means of an arm 15 to a latching element 16 that is pushed into an engagement position upon coupling the insertion device 1 to the base unit 2 , and connects the insertion device 1 to the base unit 2 in a positive fit-type manner in said engagement position. In the active state of the locking mechanism shown in FIG. 3 , displacement of the latching element 16 is prevented by means of a blockade element 17 .
Upon coupling the insertion device 1 to the base unit 2 , the blockade element 17 is moved by the base unit 2 transverse to the direction, in which the latching element 16 is displaced, i.e., it is lifted in the embodiment shown, and thus a displacement path for the latching element 16 leading towards the engagement position is released. By means of a subsequent displacement motion, the latching element 16 engages the base unit 2 , namely by being slid under engagement elements 18 that are provided for this purpose and are evident, in particular, in FIGS. 2 and 4 .
Said displacement motion is effected by a spring 19 that is shown in FIG. 3 , which spring 19 is provided as a coiled spring in the embodiment shown, preferably made of plastic, and presses onto the slider 11 . The spring 19 relaxes when the locking mechanism 11 transitions from the active state shown in FIG. 3 to its inactive state shown in FIG. 4 . In the process, the spring 19 displaces the slider 11 in the puncturing direction. Said displacement motion is transferred by means of the jointed arm 15 to the latching element 16 , which is thus made to move into its engagement position in the base unit 2 .
FIGS. 5 and 6 show another embodiment, which differs from the embodiment described above essentially only in that, in the active state of the locking mechanism 10 shown in FIG. 5 , a locking element 12 that is carried by the slider 11 engages the rotor 5 of the drive mechanism, which rotor is provided in the form of a cogwheel, and thus blocks the rotor 5 . The locking mechanism transitions to the inactive state shown in FIG. 6 by displacement of the slider 11 in the puncturing direction.
In both embodiments, a risk of injury upon handling of the insertion device 1 is reduced additionally in that, in the active state of the locking mechanism, a component of the locking mechanism 10 is situated in front (in puncturing direction) of an insertion needle 8 that is held by the insertion needle holder 7 . In the embodiments shown, said component acting as a protection element is a shift plate which simultaneously forms the latching element 16 . Upon transition of the locking mechanism 10 to its inactive state, the latching element 16 is displaced such that the insertion needle 8 is moved through an orifice that is provided in the floor of the base unit 2 and can thus be punctured into the body of a patient.
The slider 11 of the locking mechanism 10 can be displaced in the puncturing direction and is provided with a linear guidance in each of the two embodiments. In the embodiments shown, the linear guidance is provided in the form of a slit in the slider 11 through which reaches a guiding element 20 of the housing.
The actuating elements 3 can snap into a latching mechanism (not shown) at the end of a drive motion to prevent any inadvertent puncturing motion, which may lead to an injury, after uncoupling of an insertion device 1 from the base unit 2 , i.e., after an insertion.
Subsequent to a puncturing motion, the drive mechanism effects a returning motion of the insertion needle holder 7 . Preferably, the coupling between insertion device 1 and base unit 2 is released again by said returning motion. This can be attained, for example, in that the slider 11 couples to and is pulled backwards by the insertion needle holder 7 during the returning motion. The slider 11 can, for example, carry a leaf spring in an inclined orientation that is bent by the insertion needle holder during the puncturing motion such that the insertion needle holder 7 can slide over the slider 11 . During the returning motion, a leaf spring of this type can engage the insertion needle holder 7 such that the slider 11 is pulled back by the insertion needle holder 7 and thus, via the arm 15 , the latching element 16 is also pulled from its position of engagement to the base unit 2 .
LIST OF REFERENCE NUMBERS
1 Insertion device
2 Base unit
3 Actuating element
4 Toothed rack
5 Rotor
6 Connecting rod
7 Insertion needle holder
8 Insertion needle
9
10 Locking mechanism
11 Slider
12 Locking element
13 Recess
14
15 Arm
16 Latching element
17 Blockade element
18 Engagement element
19 Spring
20 Guiding element | An insertion system having a base unit for placing on the body of a patient and an insertion device that can be coupled to the base unit, wherein the insertion device comprises an insertion needle holder for holding an insertion needle and a drive mechanism for displacing the insertion needle holder in a pricking direction. According to the invention, the insertion device comprises a locking mechanism causing locking of the drive mechanism in an active state and being set to an inactive state in which the locking is released by coupling the insertion device to the base unit. | 0 |
This application claims the benefit of U.S. Provisional Application No. 60/037,364, Filing Date Feb. 6, 1997.
FIELD OF THE INVENTION
The present invention pertains generally to apparatus for diagnosing air conditioning systems. More particularly, the present invention pertains to apparatus which can determine proper functioning of an air conditioning system by using only noninvasive measurements. The present invention is particularly, but not exclusively, useful as either a mobile or a fixed based apparatus which monitors enthalpies at predetermined locations in the air flow associated with an air conditioning system for the purpose of determining and predicting system inefficiencies.
BACKGROUND OF THE INVENTION
Air conditioning systems are typically designed and engineered to obtain specific results by using conventional components which operate within certain predetermined parameters. Specifically, as one essential component, air conditioning systems will include a refrigerant, such as freon, which is repeatedly cycled through a fluid line. Not surprisingly, several processes are involved as the refrigerant is moved through the system.
For an overview of the operation of an air conditioner system, it is helpful to consider one cycle. As a start point for the cycle, consider the refrigerant to be in its gaseous state. During each cycle, the gaseous refrigerant is elevated from a relatively low pressure to a high pressure condition by a compressor. The refrigerant is then passed through a condenser coil where it is condensed at high pressure into a liquid or semi-liquid state. Next, the high pressure liquid refrigerant is passed through an expansion valve which reduces the pressure on the refrigerant. The now low pressure liquid refrigerant is then passed to an evaporator coil where it evaporates, at the low pressure, back into a gaseous state. This completes the cycle. The cycle is then repeated. It is, of course, to be appreciated that the refrigerant completely fills the fluid line and that, at all times, portions of the refrigerant are at various points in the process.
From the user's viewpoint, it is important to note that as the refrigerant evaporates, heat from its surroundings is transferred to the refrigerant. As intended for air conditioning systems, the surroundings from which the heat is transferred is the air that is to be cooled by the system.
Heretofore, whenever it has been desired or necessary to test an air conditioning system for a malfunction or an inefficiency, testing of the system has been primarily a matter of evaluating the condition of the refrigerant in the fluid line of the system. Such an evaluation has required a physical invasion of the fluid line to determine the volume of refrigerant in the system, as well as its pressure and temperature at various points in the fluid line. Obviously, an invasive evaluation of an air conditioning system can be time consuming and, in many instances, quite difficult to perform. Furthermore, it may be unnecessary.
The present invention recognizes that a physical invasion of the fluid line is not necessary for a complete and thorough analysis or evaluation of an air conditioning system. Instead, it is appreciated that an engineering evaluation of a system's component efficiencies can be made by making proper psychrometric analyses. For the present invention, such analyses rely on basic thermodynamic principles.
By definition, enthalpy (H,h) is a thermodynamic property of a working substance which is associated with the study of heat of reaction, heat capacity and flow processes. Mathematically, enthalpy is defined as h=u+pv where u is the internal energy, p the pressure and v the volume of a system. With this in mind, it is important to know that heat (Q,q) is energy that is in the process of transfer between a system and its surroundings. This energy transfer results due to temperature differences. In the context of the present invention, the relationship between enthalpy and heat can be simply stated. Namely, the heat absorbed (or rejected) in a quasistatic isobaric (i.e. constant pressure) process is equal to the difference between the enthalpies of the system in the end states of the process. For example, consider the evaporator coil of an air conditioning system. The heat (q) which is transferred from the surrounding air to the evaporator coil, during a cooling of the air, is equal to the difference between the enthalpies of air at the evaporator inlet (h inlet ) and at the evaporator outlet (h outlet ).
q=h.sub.inlet -h.sub.outlet Δ=h
A similar relationship holds for the condenser coil as well.
Due to the fact air conditioning systems are typically engineered so that the refrigerant used will transition between a fluid and a gaseous state, it is helpful to define two different types of heat pertinent to this transition. These are latent heat, which causes the change of state, and sensible heat, which does not. Specifically, latent heat is the heat which is required to change the state of a unit mass of a substance from a solid to a liquid, or from a liquid to a gas. Importantly, latent heat is not measured because it does not involve a change of temperature. Thus, without any change in temperature, the specific latent heat for a state transition is the difference in enthalpies of the substance in its two states. On the other hand, sensible heat is heat which effects a change in the temperature of a body and which is, therefore, detectable by the senses. With these definitions, it is now possible to further define the sensible heat ratio (SHR) as the ratio of latent heat to sensible heat in a process.
Using air tables well known to the skilled artisan, it is possible to determine the enthalpy of an air mass by taking readings of both the relative humidity and the dry bulb temperature of the air mass. For purposes of the present invention, the dry bulb temperature (T d ) is taken to be the equilibrium temperature of the air-vapor mixture as indicated by an ordinary thermometer. Further, relative humidity (φ) is taken to be the ratio of the partial pressure of the water vapor in a mixture to the saturation pressure of the vapor at the same temperature. Relative humidity may also be defined as the ratio of the density of the vapor in the mixture to the density of saturated vapor at the same temperature.
As can be easily appreciated, any diagnosis of an air conditioning system will involve evaluating various operational data and comparing this data with standards established by the system manufacturer. Obtaining the proper data, however, can be painstaking and labor intensive.
In light of the above, it is an object of the present invention to provide an apparatus for diagnosing and monitoring a closed air refrigeration system which relies on enthalpy readings and which, therefore, can be used without invasively entering the refrigerant fluid line of the system. It is another object of the present invention to provide an apparatus for non-invasively diagnosing a closed air refrigeration system which can be used in either a mobile or a fixed base configuration for, respectively, making an instantaneous or a continuous evaluation of an air conditioning system. Still another object of the present invention is to provide an apparatus for non-invasively diagnosing a closed air refrigeration system which is easy to use, relatively simple to manufacture and comparatively cost effective.
SUMMARY OF THE PREFERRED EMBODIMENTS
An apparatus for non-invasively diagnosing and monitoring a closed air refrigeration system essentially includes at least one sensing unit and a computer. The sensing unit includes an air flow channel and it has a detector which is mounted on the unit in the air flow channel. Specifically, the detector includes a thermometer for taking the dry bulb temperature (T d ) and a relative humidity meter which measures the relative humidity (φ) of air flowing through the air channel. The detector may also include devices for determining volumetric air flow through the sensing unit. These readings, the dry bulb temperature reading, the relative humidity reading and the volumetric flow are electrically or electronically transmitted from the detector to the computer for analysis.
A typical closed air refrigeration system to be monitored by the present invention includes an evaporator and a condenser. Further, the evaporator has an evaporator coil, and it has a blower which directs relatively warm air from the air space that is being refrigerated through an inlet and over the evaporator coil. In this process, heat is transferred from the air to the evaporator coil. Thus, the air is cooled. The evaporator also has an outlet which directs the now-cooled air back into the air space that is being refrigerated. In a somewhat similar arrangement, the condenser of an air conditioning system has a condenser coil which is immersed in a fluid heat sink. Depending on the needs of the system, the heat sink may be either gaseous or liquid. Typically, however, the heat sink is gaseous and the condenser includes a blower which directs air from the outside heat sink through an intake and over the condenser coil. As this air passes over the condenser coil, heat is transferred from the condenser coil to the air. The now-heated air is then passed through an exhaust and back into the heat sink.
As intended for the present invention, both the evaporator and the condenser can be monitored and evaluated by sensing units. For example, to monitor and evaluate the evaporator, a sensing unit is positioned over the evaporator inlet and readings are taken of the dry bulb temperature and relative humidity of the air entering the inlet. As indicated above, the volumetric air flow rate may also be measured. These readings are then transmitted to the computer where they are used to calculate an enthalpy for air entering the evaporator inlet. The sensing unit is then positioned over the evaporator outlet and readings are taken of the dry bulb temperature, the relative humidity, and the volumetric flow rate of the air leaving the outlet. These readings are also transmitted to the computer where they are used to calculate an enthalpy for the air leaving the evaporator outlet. In an alternate embodiment of the present invention two separate sensing units can be used and simultaneously positioned over the evaporator's inlet and outlet. With this embodiment the enthalpies for both the inlet and outlet can be determined simultaneously.
For a diagnosis of the air refrigeration system, the evaporator inlet enthalpy is first compared with the evaporator outlet enthalpy in the computer. Based on this comparison, it is determined whether the total heat transfer (Q TOT ) of the evaporator is as rated by the manufacturer. If Q TOT is as rated, then the air flow is checked to determine whether there might be an air flow problem, such as a dirty evaporator coil. In cases where Q TOT is correct and there is no air flow problem, a sensible heat ratio (SHR) for the evaporator is calculated. Specifically, if both Q TOT and the SHR are as rated by the manufacturer, then the air refrigeration system is properly operable. On the other hand, if either Q TOT or the SHR are not as rated for the system, additional diagnostics involving superheat and subcool calculations need to be considered. This will involve data from the condenser. Accordingly, the enthalpies for the air entering the intake of the condenser and the air leaving through the exhaust of the condenser need to be determined and compared in a manner similar to that disclosed above for the evaporator. Thus, incidentally, the efficiency of the condenser can also be determined.
To calculate superheat for the air refrigeration system, readings of Q TOT for the evaporator and for the suction line temperature, T s , are required. Recall, Q TOT for the evaporator was previously determined by calculating the change in enthalpies between the evaporator inlet and the evaporator outlet. The suction line temperature, T s , is taken non-invasively off the fluid line between the evaporator coil and the compressor. The computer then uses this data to determine superheat. In a similar manner, Q TOT for the condenser is determined, and the liquid line temperature, T L , is obtained. Specifically, the liquid line temperature, T L , is taken off the fluid line between the condenser coil and the expansion valve. The computer then uses this data to determine subcool. The superheat and subcool, which are calculated as indicated above, are then compared to the rated superheat and the rated subcool for the system. If the measured superheat is lower than the rated superheat, or the measured subcool is higher than the rated subcool, the indication is that the air refrigeration system is overcharged with refrigerant. On the other hand, if the measured superheat is higher than the rated superheat, or the measured subcool is lower than the rated subcool, the indication is that the system is undercharged with refrigerant.
It is to be appreciated that the apparatus of the present invention may be either mobile or fixed base. In a mobile configuration the sensing units may be selectively positioned over the evaporator inlet or outlet. Likewise they may be selectively positioned over the condenser intake or exhaust. For the mobile configuration, the computer may also be mobile. On the other hand, for the fixed based configuration the computer can be either permanently placed on site with the sensing units or remotely positioned at a centralized location where it can monitor several systems. In either case, for the fixed base configuration, each sensing unit can be permanently positioned over a respective inlet, outlet, intake, or exhaust in the system being monitored.
BRIEF DESCRIPTION OF THE DRAWINGS
The novel features of this invention, as well as the invention itself, both as to its structure and its operation, will be best understood from the accompanying drawings, taken in conjunction with the accompanying description, in which similar reference characters refer to similar parts, and in which:
FIG. 1 is a schematic diagram of a typical air refrigeration system with air flow sensing units of the present invention positioned at predetermined critical locations in the system;
FIG. 2 is a perspective view of an environment inside a structure which is serviced by an air refrigeration system, with portions of the structure broken away for clarity;
FIG. 3 is a block diagram showing a diagnostic analysis scheme as contemplated by the present invention;
FIG. 4A is a graph showing a generalized relationship between temperature and heat for a refrigerant during its transition between a gaseous and a liquid state at different pressures;
FIG. 4B is a graph showing a generalized relationship between temperature and heat for moisture during its passage over an evaporator coil of an air refrigeration system; and
FIG. 5 is a specialized graph showing the interation between superheat and subcool relative to their respective saturation points.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring initially to FIG. 1, a schematic of the apparatus in accordance with the present invention is shown in its operational environment and is generally designated 10. More specifically, the schematic of the apparatus 10 is shown in FIG. 1 superimposed over the schematic of a typical air refrigeration system 12. For purposes of the present invention it is instructive to identify the salient components of the system 12 and to briefly discuss their interactive cooperation.
In overview the air refrigeration system 12 includes an evaporator 14, a compressor 16, a condenser 18 and an expansion valve 20 which are all interconnected in a closed loop by the fluid line 22. Specifically, the evaporator 14 includes an evaporator coil 24, which is actually part of the fluid line 22. The evaporator 14 also includes and evaporator inlet 26 which directs air over the coil 24, and an evaporator outlet 28 which directs air away from the coil 24. A blower 30 is included in the evaporator 14 to cause air to flow into the evaporator 14 through the inlet 26, across the coil 24, and from the evaporator 14 through the outlet 28. Next in line along the fluid line 22 is the compressor 16. The compressor 16 is of a type well known in the pertinent art and includes a piston 32 which compresses, and thereby increases the pressure of, the fluid in fluid line 22. As shown in FIG. 1, the fluid line 22 connects the compressor 16 with the condenser 18.
The condenser 18 of air refrigeration system 12 includes a condenser coil 34 which, like the evaporator coil 24, is actually part of the fluid line 22. Additionally, the condenser 18 has an intake 36 which directs air over the coil 34, and it has an exhaust 38 which directs air away from the coil 34. Like the evaporator 14, the condenser 18 includes a blower 40 which causes air to flow into the compressor 18 through the intake 36, across the coil 34, and from the condenser 18 through he exhaust 38. Next in line along the fluid line 22 is the expansion valve 20 which is of a type well known in the art. With an opposite effect to that caused by compressor 16, the expansion valve 20 reduces pressure on the fluid in fluid line 22. Thus, in a manner well known in the pertinent art, the fluid in fluid line 22 of air refrigeration system 12 cycles through the system 12 between a high pressure condition as it passes through condenser 18, and a low pressure condition as it passes through evaporator 14. The demarcation between high and low pressure is generally indicated in FIG. 1 by the pressure line 42. High pressure in the system 12 being on the condenser 18 side of pressure line 42, and low pressure in the system 12 being on the evaporator 14 side of pressure line 42. Further, it should be noted that while under high pressure, the fluid in the fluid line 22 changes state (condenses) from a gas to a liquid. On the other hand, while at the lower pressure, the fluid in fluid line 22 changes state (evaporates) from a liquid to a gas. The demarcation between liquid and gas is generally indicated in FIG. 1 by the liquid line 43.
FIG. 1 shows there are four separate sensing units 44a-d which can be respectively positioned over the evaporator inlet 26, the evaporator outlet 28, the condenser intake 36 and the condenser exhaust 38. It is to be appreciated that the apparatus 10 of the present invention can include all four such sensing units 44a-d or, alternatively, it can include as few as one such sensing unit 44. When more than one sensing unit 44 is used, they will all be essentially identical. Therefore, only sensing unit 44a will be discussed here, with the understanding that in all important respects the sensing units 44b-c are the same as sensing unit 44a.
As shown in FIG. 1, sensing unit 44a includes an air guide 46 and a detector 48. Further, the detector 48 is electronically connected via a line 50 with a computer 52. As shown in FIG. 1, the line 50 is a hard wire connection. It will be appreciated, however, that this communication link can be an rf (radio frequency) wireless system. As for the air guide 46, it can be made of any material which will divert or direct air flow. Preferably, the air guide 46 can be made of a light weight material, such as a fabric. Regardless of the material that is used, it is necessary that the air guide 46 be formed with a port 54 which can be either selectively or permanently engaged with the evaporator 14 or the condenser 18. In FIG. 1, the sensing unit 44a is shown engaged with the evaporator inlet 26. As indicated above, sensing unit 44a, or a similar sensing unit 44, can also be engaged with evaporator outlet 28, condenser intake 36 or condenser exhaust 38.
When properly engaged with either the evaporator 14 or the condenser 18, the sensing units 44 direct air in a predetermined manner. For example, when sensing unit 44a is engaged with evaporator inlet 26, the air which flows through the sensing unit 44a (indicated by the arrows 56) is the same volume of air that flows into the evaporator 14. Also, it is the same volume of air that flows out of the evaporator 14 through evaporator outlet 28.
As also shown in FIG. 1, the detector 48 is positioned near the port 54 of sensing unit 44a. In one embodiment of the apparatus 10, the detector 28 is centered in the air guide 46. It happens, however, that regardless where the detector 28 is specifically located on the sensing unit 44, an important consideration is that the detector 28 be subjected to a representative sample of the air flowing through the sensing unit 44a. This can be done in several ways. For example, air sampling can be done by selectively positioning a plurality of individual detectors 28 in the vicinity of port 54 of the sensing unit 44, and then averaging the readings from these various detectors 28. In another manner, sampling can be done by redirecting air samples from various locations in the air guide 46 to a single detector 28. Readings are then made by the single detector 28. In all cases, the detector 28 includes a dry bulb thermometer (not shown), which is of a type well known in the pertinent art, and it includes a relative humidity meter (not shown), which is also of a type well known in the pertinent art. Additionally, the detector may include a device (not shown) for taking air flow temperature, pressure, or air flow velocity to determine the actual volumetric air flow through the sensing unit 44. Accordingly, the readings which are taken by the sensing unit 44 are the temperature and the relative humidity, and volumetric flow of the air flowing through the sensing unit 44.
For the present invention, the temperature and relative humidity readings which are obtained by the sensing unit 44 are electronically transmitted via line 50 to the computer 52. Using predetermined data evaluation programs in the computer 52, the dry bulb temperature reading and the relative humidity reading of the air flowing through the sensing unit 44 are converted into an enthalpy reading. In the case where the sensing unit 44a is positioned over the inlet 26 to evaporator 14, the enthalpy is determined for the air entering evaporator inlet 26. In a similar manner, respective enthalpy readings can be obtained for the evaporator outlet 28, the condenser intake 36 and the condenser exhaust 38.
Referring to FIG. 2 it can be seen how the apparatus 10 of the present invention may be employed. Specifically, for the structure 58, an airspace 60 is shown which is to be cooled by the air refrigeration system 12. In this environment, to evaluate and monitor the evaporator 14 of the system 12, a sensing unit 44a is positioned over the inlet 26 in airspace 60 which leads to the evaporator 14. This connection is sometimes referred to as the supply line. At the same time, a sensing unit 44b is positioned over the outlet 28 in the airspace 60 which leads from the evaporator 14. This connection is sometimes referred to as the return line. With the sensing units 44a and 44b in place, readings are taken from the air that is supplied to, and the air that is returned from, the evaporator 14. This air is respectively designated in FIG. 2 with the arrows 56 and 56'.
As also shown in FIG. 2, the condenser coil 34 of air refrigeration system 12 is immersed in a heat sink 62. Specifically, air from the heat sink 62, which is generally designated by the arrow 64, is pulled into the system 12 through intake 36 and directed over the coil 34. After receiving heat from the coil 34, this same air, now designated by the arrow 64', is returned back to the heat sink 62. As is to be appreciated with cross reference to FIG. 1, the condenser 18 can be monitored and evaluated by respectively placing sensing units 44c and 44d over its intake 36 and exhaust 38. Appropriate readings can then be taken of the air 64 and 64'.
The process for evaluating an air refrigeration system 12 will, perhaps, be best appreciated with reference to FIG. 3. There it will be seen, as indicated by block 66, that an evaluation starts by obtaining data in the form of various readings that are taken by the detector unit 48 of the associated sensing 44. Specifically, it is important that the dry bulb temperature, T d , and the relative humidity, φ, be obtained by each sensing unit 44. Additionally, barometric pressure can be easily determined and used to refine other readings, if necessary. Also, the volumetric air flow rate can be obtained. As indicated above, with these readings, air tables that are programmed into computer 52 can be used to determine the enthalpy, h, of air passing through the particular sensing unit 44. For instance, by taking separate readings of the air 56 and air 56', the enthalpy of air at inlet 26 (h 1 ) and the enthalpy of air at outlet 28 (h 2 ) can be determined. This acquisition is indicated by block 68. Block 70 next indicates that the difference between the enthalpies h 1 and h 2 is taken as the total heat, Q TOT , which is exchanged between the conditioned air 56-56' and the evaporator coil 24. How this total heat, Q TOT , is used, needs further evaluation in the context of the heat transfer process between air 56 and evaporator coil 24.
In order to more fully appreciate the heat transfer process that is being evaluated by the apparatus 10 of the present invention, reference is momentarily directed toward FIGS. 4A and 4B. Specifically, FIG. 4A shows the general relationship between temperature and heat for a refrigerant in the fluid line 22 of air refrigeration system 12. More specifically, line 72a shows a generalized temperature/heat relationship at the lower pressures experienced in fluid line 22 on the evaporator 14 side of the pressure line 42 in FIG. 1, and the line 72b shows a generalized temperature/heat relationship at the higher pressures experienced in fluid line 22 on the condenser 18 side of the pressure line 42. As shown, the lines 72a and 72b show temperature/heat relationships during a transition in state between gas and liquid at the different pressures. Similarly, line 74 in FIG. 4B shows a generalized temperature/heat relationship for moisture at atmospheric pressure as air transitions in state between a gas and a liquid.
In FIG. 4B it will be seen that as air decreases in temperature from T 1 to T 2 , movement along the line 74 from point 76 to point 78 shows a corresponding change in the quantity of heat from point 80 to point 82. This particular quantity of heat is sensed by the temperature change from T 1 to T 2 and is, therefore, sensible heat, Q sensible . According to FIG. 4B, a further loss of heat from point 82 to point 84 will not cause a change in temperature. Thus, this lost heat is latent heat, Q latent . It will also be noted that a further loss of heat, e.g. past the point 86, will result in a transition from the gaseous state (to the right of point 82) to a liquid state (to the left of point 86). FIG. 4A, can be similarly analyzed for the refrigerant in line 22. FIG. 4A is, however, also instructive on the physical transitions between states for refrigerant in fluid line 22. For instance, point 88 on line 72a is representative of the refrigerant as it leaves the evaporator coil 24. The transition from point 88 to point 90 on line 72b represents the increase in pressure on the refrigerant in fluid line 22 by the action of compressor 16. As the high pressure refrigerant condenses in condenser coil 34, the loss of heat to heat sink 62 is represented by movement from point 90 to point 92. The release in pressure afforded by expansion valve 20 is indicated in FIG. 4A by a movement from point 92 on line 72b to the point 94 on line 72a. At point 94, the refrigerant is entering the evaporator coil 24. As the refrigerant moves through the evaporator coil 24, air 56 also flows over the coil 24. Consequently, heat from the air 56 is added to the refrigerant to cause movement along the line 72a back to the point 88. The heat transferred from air 56 is the total heat, Q TOT , and, as stated above, Q TOT is equal to the difference in enthalpies h 1 and h 2 . Comparing FIG. 4A with FIG. 4B, it also happens that Q TOT =Q sensible +Q latent . With the above in mind, return now to FIG. 3 and reenter the process at the point where Q TOT for the evaporator 14 has been determined.
As indicated by block 96, the measured Q TOT for evaporator 14 is compared with the rated Q TOT . Assume for the moment that the measured Q TOT is as rated. Blocks 98, 100 and 102 in FIG. 3, indicate that with proper Q TOT the volumetric air flow rate is checked and, if underrated, the conclusion to be made is that there is either a dirty coil (i.e. evaporator coil 24, or condenser coil 34, as appropriate), a dirty blower (i.e. blower 30 or 40), or a malfunctioning blower motor.
Block 104 in FIG. 3 indicates that once the total heat Q TOT has been determined, preprogrammed psychrometric tables in computer 52 can be used in conjunction with temperature changes (e.g. T 1 and T 2 in FIG. 4B) to determine the sensible heat, Q sensible . With a value for Q sensible , a sensible heat ratio, SHR, can be determined (see blocks 106 and 108). Inquiry block 110 then indicates that if the SHR is as rated for the system 12 (usually equal to or greater than 90%), then (as indicated in conclusion block 112) the system 12 is OK. No further testing is then necessary. On the other hand, if conclusion block 112 can not be reached, i.e. Q TOT or SHR are not as rated, further analysis of the system 12 should be made.
To make an additional evaluation of the system 12, block 114 requires that the suction line temperature T S and liquid line temperature T L be determined. With reference back to FIG. 1 it will be seen that the suction line temperature, T S , is preferably taken on the fluid line 22 at the inlet to compressor 16. Also, FIG. 1 indicates that the liquid line temperature, T L , is preferably taken on the fluid line 22 at the side of the condenser coil 34 that is opposite the compressor 16. The suction line temperature T S and the liquid line temperature T L can then be respectively used with the changes in enthalpies at the condenser coil 34 and the evaporator coil 24 to determine set points for superheat and subcool of the system 12. In the context of the present invention, the concepts of superheat and subcool will, perhaps, be best appreciated with reference to FIG. 5.
In FIG. 5 it will be seen that a continuous scale 115 is provided which is actually two interconnected and mutually dependent scales. These interconnected scales are actually a representative superheat scale 116 and a representative subcool scale 118. Further, a saturation point 120 (0° F.) is shown for superheat scale 116, and a saturation point 122 (0° F.) is shown on the subcool scale 118. As shown, the continuous scale 115 is mounted on a base 124 such that the saturation point on the subcool scale 118 is aligned with approximately 30° F. on the superheat scale 116. It is to be appreciated that any movement of superheat scale 116 on base 124 results in a simultaneous and corresponding movement of the subcool scale 118, and vice versa. With this in mind, consider that the scale 115, is positioned on base 124 in FIG. 5 (as stated above), so as to correspond with a particular ambient temperature. Parenthetically, although not considered in this analysis, if the ambient temperature changes, the location of the combined scale 115 will move accordingly on the base 124 (i.e. 0° F. subcool will no longer be aligned with 30° F. superheat).
For a properly operating air refrigeration system 12, at a particular ambient temperature, the system 12 will have a particular rated superheat temperature, and a particular rated subcool temperature. For example, in FIG. 5, the rated superheat temperature might be 18° F., as indicated by the solid arrowhead 126 on superheat scale 116 (this is a set point). Also, in this example, the corresponding factory rated subcool temperature might be 8° F., as indicated by the solid arrowhead 128 on subcool scale 118 (this is another set point). These, of course, are the expected readings which will be obtained if the system 12 is operating properly under predicted conditions for temperature (T d ) and pressure.
At this point it is important to note that for an operator to obtain the superheat and subcool readings for an operating system 12, the operator needs to obtain the suction line temperature T S and liquid line temperature T L as indicated in block 114 of FIG. 3. Further, using calculations known in the pertinent art, T S and T L can be evaluated with the changes in enthalpies (i.e. Q TOT ) and calculated by computer 52 to obtain measured operational readings for the superheat and subcool of the system 12. The measured superheat and measured subcool then need to be respectively compared with the rated superheat and the rated subcool for system 12 (see blocks 134 and 136). For instance, consider that the readings obtained indicate a superheat of 21° F., as indicated by clear arrowhead 130 on superheat scale 116, and a subcool of 6° F., as indicated by clear arrowhead 132 on subcool scale 118. Decision blocks 134 and 136 show that these particular conditions are indicative of an undercharge in the freon (see block 138). On the other hand, if the obtained readings are, respectively, 15° F., as indicated by the divided arrowhead 140 on superheat scale 116, and 10° F. as indicated by the divided arrowhead 142 on subcool scale 118, then block 144 shows that the system 12 is overcharged.
As shown in FIG. 3, it may happen that while Q TOT or SHR may not be as rated for system 12, the measured superheat and subcool may, nevertheless, be as rated. If so, block 146 indicates some additional testing or inspection must be done. Specifically, but only by way of example, there may be leaks in the system 12 which have been undetected, or the compression ratio of the compressor 16 may be off.
While the particular apparatus for non-invasively diagnosing a closed air refrigeration system as herein shown and disclosed in detail is fully capable of obtaining the objects and providing the advantages herein before stated, it is to be understood that it is merely illustrative of the presently preferred embodiments of the invention and that no limitations are intended to the details of construction or design herein shown other than as described in the appended claims. | An apparatus and method for noninvasively diagnosing a closed air refrigeration system includes a sensing unit which can be selectively placed over the evaporator inlet duct and the evaporator outlet duct to respectively measure the evaporator inlet enthalpy and the evaporator outlet enthalpy. Using both of these enthalpies, a computer calculates a sensible heat ratio for the evaporator which is useable to diagnose the system. Similarly, the sensing unit can be selectively placed over the condenser intake and condenser exhaust to measure the condenser intake enthalpy and the condenser exhaust enthalpy. Using these enthalpies, the computer calculates a sensible heat ratio for the condenser which is useable to further diagnose the system. Further, superheat and subcool set points can be calculated and compared with rated set points to evaluate the system. In an alternate embodiment, separate sensing units can be used simultaneously to measure the various enthalpies. | 5 |
CROSS-REFERENCE TO A RELATED APPLICATION
This application is a National Phase Patent Application of International Patent Application Number PCT/EP2012/063985, filed on Jul. 17, 2012, which claims priority of German Patent Application Number 10 2011 108 624.6, filed on Jul. 27, 2011.
BACKGROUND
The invention relates to a connecting device for temporarily connecting two preferably plate-like parts, in particular for connecting two parts to be glued and/or to be riveted. Furthermore, the invention relates to a needle for such connecting devices, which can guarantee a reduced area pressing at the parts to be connected. The preferred field of application of the invention is the aerospace sector.
A known connecting device of the principle according to the invention, which is used in the aviation industry, is described in DE 20 2010 015 746. It comprises a guiding body mounted torque-proof in a housing, the guiding elements thereof engage into guiding openings of the needle carrier. The needle carrier carries two needles distanced from each other with terminal sided hook-shaped needle tips. A spreading of the needle tips occurs if the needle tips projecting at first beyond the end of the spreading tongue connected to the guiding body are moved by the driving element axially into the housing. For this reason the needle carrier and the driving element comprise screw threads engaging into each other.
This connecting device has the disadvantage that the spreading tongue covers a note-worthy part of the hole cross section, which is provided for guiding the needles transferring the tensioning force. The spreading tongue itself can transfer a tensioning force. It is furthermore of a disadvantage that the length of the spreading tongue has to be adapted to the thickness of the parts to be tensed or to be connected.
SUMMARY
An object of the present invention is to develop an improved connecting device and a novel system of needles with hook-shaped abutments, which provides an enlarged abutment area of the needle tips at a predetermined diameter provided for the needles and thus can reduce the area pressing.
The essence of the connecting device according to an exemplary embodiment of the invention consists in the following feature combination:
The connecting device, which is based on a as such known combination of housing, hook-shaped abutment with integrated supporting areas at the free ends of the assigned needles and a drive element for axial adjustment of the needles as well as for spreading the hook-shaped needle tips, is essentially characterized by
at least two needles, which are firmly connected on the base side to respective separate carriers, of which at least one carrier is operatively connected to the drive element such that the needles can be adjusted relative to each other in axial direction; an axial movement of the needles in a starting position before the connecting device is tensed with the parts to be connected, and in fact with needle tips moved axially to each other, while in the tensed position the needle tips are opposite to one another such that the supporting areas thereof are situated at the same axial level; integrated elevations and depressions in the area of the needle tips in respect to their areas facing each other, wherein said elevations and depressions are nested into each other in a space-saving manner in the starting position of the needles, and wherein the elevations slide on each other during the transition into the tensed position of the needle tips and thus press the needle tips apart from each other such that the supporting areas of the needle tips overlap the assigned area sections of the parts to be connected on the edge side of the assembly hole.
According to a preferred variant of the invention, a first needle-carrier-combination consisting of a first shorter needle, which is firmly connected to a first carrier, and a second needle-carrier-combination consisting of a second longer needle, which is firmly connected to a second carrier, are nested into each other, wherein the first carrier comprises a lateral free punch or a passage opening for the second larger needle adapted to the cross section of the needle such that the two carriers can be arranged axially one after the other and the two needles can be arranged preferably next to each other.
Guiding openings continuing in alignment in the two carriers in combination with guiding bodies of a support-guiding body-combination, wherein the guiding bodies are inserted into the carriers in a sliding movable manner, provide the anti-twist protection of both needle-carrier-combinations.
A further preferred feature of the invention is that the first carrier comprises a coupling element which can be inserted into a coupling opening of the second carrier. A limitation of the axial movability of the needles is guaranteed when interacting with a contact area arranged in the region of said coupling opening and a projection of the coupling element. In this contact position, the supporting areas of the needle tips are aligned to each other and are provided for tensing the parts to be connected.
At first, however, in the starting position of the needles not yet tensed, the first and the second carrier are arranged next to each other without a distance or with a small distance, wherein the supporting areas of the needle tips do not yet align to each other and are thus also not yet spread radially.
The carrier comprise a screw thread for axial adjustment of the carrier and the movement of the needles connected thereto, wherein said screw thread is operatively connected to an assigned internal screw thread of the drive element. The screw thread of the drive element is preferably formed as an internal thread arranged sectional in order to achieve a simple demoulding of a drive element injection molded of plastic.
A cylindrical area without a thread is arranged upstream of the screw thread at the open end of the sleeve-shaped drive element, the height thereof corresponds at least to the height of the first carrier. Thereby it is guaranteed that at first the second carrier with the longer needle is moved with its tip onto the axial level of the needle tip of the shorter needle. Only then both needle tips are adjusted synchronously until the connecting device is tensed with the parts to be tensed. The drive element is driven via a tool intersection at the bottom of the drive element, where a rotating tool can be positioned.
In an alternative embodiment a first carrier is provided with an external thread, which can be engaged with the internal thread of the drive, and a second carrier, which is preloaded by means of a spring element in direction of the first carrier arranged upstream. This variant has the advantage that no measures have to be provided in order to guarantee an engagement of the threads of the needle carriers into the thread of the drive part which is coordinated between the needle carriers.
The needles comprise preferably in the area of the needle tips projections and depressions, which engage alternating into each other, if the needle tips are moved axially to each other. Thereby, the needle tips cover a comparatively small cross section and almost completely fill out the assembly holes in the plane of the supporting areas of the needle tips. If the needle tips are located axially on the same level, thus the projections and depressions do not engage any longer with each other, but at least do not engage anymore completely into each other, the needle tips are pressed apart from each other by the projections resting on top of each other. As a consequence, the supporting areas of the hook-shaped abutments of the needle tips overlap the assigned areas of the parts to be connected.
A further invention relates to a novel needle system of the previously described connecting device. At least two needles, the tips thereof are formed as hook-shaped abutments, comprise at the areas facing each other a contour deviating from the axial moving plane, in particular in form of projections and depressions. They engage alternating into each other in a nested manner, if the needle tips are moved axially to each other. However, they do not engage or only partially engage with each other, if the needle tips are located axially on the same level. The needle tips are then pressed apart from each other by the projections resting on top of each other, whereby the supporting areas of the needle tips overlap the assigned areas of one of the parts to be connected.
The projections and depressions or the like are preferably integrated in one piece into the needles made of plastic or metal, in particular in the region of the needle tips. Plastic needles should be formed fiber-enforced in order to be able to absorb high mechanical loadings. Plastic needles can be, in a simple manner, integral part of the assigned carrier.
If the needles are made of a metallic material, for instance in form of a casting or a cold impact extrusion part, form-fit regions should be formed on the base side for a stable embedding of the needles into a carrier of plastic. The needles and the carrier can be made of course also as one piece metallic castings.
For minimizing the area pressing, the sum of the cross sections of all needle tips in the plane of their supporting areas should correspond approximately to the cross section of the assembly holes in the parts to be connected. It is recommended that the cross sections thereof cover in sum preferably more than 90% of the cross section of the assembly hole.
In a particular embodiment of the needles in the region of their tips the sum of the cross sections of all needle tips in the plane of their supporting areas can be larger than the cross section of the assembly holes in the parts to be connected. This is achieved by projections in the region of the needle tips, which are formed by the needle tips themselves by a curved course of the contour of the needles continuing opposite to the locking direction of the supporting areas. Thereby, the projections of the shorter needles engage into the assigned free spaces of the longer needles, while the projection of the longest needle overlaps the needle tips of the other needles.
The areas of the needles or needle tips facing each other comprise preferably guiding contours directed essentially axially and engaging form-fit into each other in order to guarantee a defined positioning of the needle tips during the adjustment process. For this reason the needle tips are connected elastically to the needle shafts.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is explained in the following by means of embodiments and the illustrated Figures.
FIGS. 1 a , 1 b show perspective views of a connecting device,
FIGS. 2 a , 2 b show explosion illustration of the singular parts of the connecting device,
FIGS. 3 a , 3 b show perspective views of the first needle-carrier-combination with a passage opening for the second needle,
FIGS. 4 a , 4 b show perspective views of the second needle-carrier-combination with a coupling opening for the passage of a coupling element of the first carrier,
FIGS. 5 a , 5 b show perspective views of the two needle-carrier-combination with spread needle tips nested into each other,
FIGS. 6 a , 6 b show perspective illustration of a carrier side view of the second needle-carrier-combination as well as an enlarged illustration of the coupling opening,
FIGS. 7 a , 7 c show perspective views of the needle-carrier-combinations with non-spread needle tips nested into each other,
FIG. 7 b shows enlarged illustration of the needle tips moved to each other and nested into each other on the attachment side,
FIGS. 8 a -8 c show perspective views of the needle-carrier-combinations nested into each other in combination with the support-guiding body-combination, wherein it shows:
FIG. 8 a shows non-spread needle tips moved maximal to each other,
FIG. 8 b shows needles with a beginning spreading of the needle tips partially moved to each other,
FIG. 8 c shows needle tips on the same height (not moved anymore to each other) and spread apart,
FIGS. 9 a -9 c show different perspective views of the drive element acting onto the needle-carrier-combination,
FIGS. 10 a , 10 b show perspective views of the supporting guiding body combination with form-fit elements to the external housing,
FIGS. 11 a , 11 b show perspective views of the external housing,
FIGS. 12 a , 12 b show side views of the needle-carrier-combination nested into each other with non-spread and spread needle tips,
FIGS. 13 a -13 e , show principal illustration of different variants of needles nested into each other from the back side via form-fit regions, the tips thereof comprise in the region of their supporting area in sum a cross section, which is larger than the cross section of the assembly hole,
FIG. 14 shows principle illustration of a variant of needles nested from the backside via a region reduced in its thickness,
FIGS. 15 a -15 b show cross section of a connecting device with only one driven needle carrier and needles according to the principle illustrated in the FIGS. 13 a to 13 c,
FIG. 15 c shows top view of the contour of the driven needle carrier with its lateral free punch for introducing the other needle.
DETAILED DESCRIPTION
The perspective views of the connecting device shown in FIGS. 1 a and 1 b illustrate two so-called sewing needles 10 , 20 in a position in which a tensioning with the parts (not shown here) could occur. Thereby, the needle tips 100 , 200 are on the same axial level in respect to the supporting area 301 , which provides the contact to one of the parts to be connected. Should the supporting area 301 be contaminated by a glue then, by exchanging part 3 in a simple manner, the advantage of the modular system can be used and costs can be saved.
The housing 5 of the connecting device comprises on the opposite side a form-fit region 51 , which serves in connection with the rotating tool as anti-twist protection, if the adjusting force is transferred via a second form-fit element 41 . This second form-fit element 41 is shaped at the bottom 40 of the drive element 4 which is provided for adjusting the needles 10 , 20 and tensing the needle tips 100 , 200 to the in particular plate-like parts to be connected.
All parts of the connecting device are deducible from FIGS. 2 a and 2 b . Accordingly, a first needle-carrier-combination 1 is provided, which consists of a needle 10 and a carrier 11 , wherein both are firmly connected to each other. The needle 10 comprises a circular sectional cross section, which—as far as possible—should be approximately a semi-circle in order to use the available space as good as possible and thus to maximize the carrying capacity thereof. On the essentially flat side of the needle 10 a passage opening is formed in the carrier 11 through which the needle 20 of the second needle-carrier-combination 2 can be guided.
Both carriers 11 , 21 comprise screw threads 110 , 210 at their cylindrical external faces for the purpose of engaging into assigned thread segments 43 of the drive element 4 . Furthermore, aligned guiding openings 112 , 212 of both carriers 11 , 21 form in connection with the inserted guiding bodies 31 of the support-guiding body-combination 3 an anti-twist protection for the needles 10 , 20 . Thereby, the needles 10 , 20 pass the opening 300 of the supporting body 30 . The supporting body 30 comprises on the one hand form-fit elements 302 , which form in connection with assigned form-fit elements 502 of the housing 5 (see FIG. 11A ) a further anti-twist protection.
The assembly of parts 1 to 5 is to be carried out in the following order:
At first, the first and the second needle-carrier-combination 1 , 2 are nested with each other by inserting the second needle 20 into the passage opening 111 , and indeed until both carriers 11 , 21 rest on top of each other. In this status, the end of the second needle tip 200 projects somewhat beyond the end of the first needle tip 10 , wherein the protrusions 101 , 201 and depressions 102 , 202 incorporated into the flat sides of the needles 10 , 20 engage into each other in a space saving manner. Thereby, the needle tips 100 , 200 are essentially directly adjacent to each other with their flat sides and comprise the smallest radial extension.
The needle-carrier-combinations 1 , 2 joint such are now nested with the support-guiding body-combination 3 by inserting the needles 10 , 20 from the side of the guiding body 31 through the opening 300 of the supporting body 30 until the carrier 11 rests against the supporting body 30 . Thereby, the guiding bodies 31 reach through the guiding openings 112 , 212 and form an anti-twist protection in order to be able to guarantee the drive force for adjusting the needles 10 , 20 by means of the rotatable drive element 4 .
In the next step, the combination of parts 1 , 2 and 3 is inserted into the drive element 4 , wherein the carrier 21 abuts at first against the first thread of the internal thread segment 43 and fills out largely the cylindrical space 45 (which does not comprise a thread). Due to a screwing movement the external thread 210 of the carrier is brought into engagement with the internal thread 43 of the drive, and indeed until the first carrier 11 is completely received by the space of the cylindrical face 45 . In this status, the supporting body 30 rests on the outer edge of the drive element.
Finally, the combination of the parts 1 , 2 , 3 and 4 is inserted from the side of the form-fit region 51 into the opening 510 of the housing 5 until the supporting area 301 projects through the front-sided opening 500 , wherein the supporting body 30 of the support-guiding body-combination 3 engages with its form-fit elements 302 in assigned form-fit elements 502 (see FIG. 11A ) and forms an anti-twist protection. A protection not illustrated in the FIGS. 2 a , 2 b shall guarantee that the axial position of the drive element 4 is maintained in the housing 5 .
FIG. 3 a , 3 b or 4 a , 4 b show a possible embodiment of needle-carrier-combinations 1 and 2 , the assembly thereof is illustrated in different axial positions of their elements in the FIGS. 5 a to 7 c.
Accordingly, the needle tips 100 , 200 of the needles 10 , 20 comprise at their sides directed outwards conical or cone-sector shaped formed areas 102 , 203 which lead to radial continuing supporting areas 104 , 204 . On the sides of the needles 10 , 20 directed inwards (which are formed essentially flat) projections 101 , 201 and depressions 102 , 202 are incorporated in the region of the needle tips 100 , 200 or in close proximity thereto, which engage alternating into each other in a starting position of needles 10 , 20 such that the needle tips 100 , 200 adjoin each other at their sides directed inwards. See also FIGS. 7 a to 7 c . In this this position, the needle tips 100 , 200 occupy the smallest radial cross section, which is somewhat smaller than the cross section of the assembly holes M of the parts to be connected. Thereby, the carriers 11 , 21 rest on top of each other and the second needle tip 200 projects somewhat beyond the first needle tip 100 .
Furthermore, means are provided which delimit a relative movement of the needles 10 , 20 or their needle tips 100 , 200 such that the supporting areas 104 , 204 thereof can be displaced exactly on the same axial level, wherein the projections 101 , 201 slide on each other and spread thereby the needle tips 100 , 200 apart. Only then, a tensing of the parts to be connected can occur.
For controlling the relative movement of the needles 10 , 20 a coupling element 12 with a coupling region 120 forming a projection is provided at the carrier 11 , which can engage into a coupling opening 211 . The coupling opening 211 comprises according to the detailed illustration of the FIGS. 6 a , 6 b a round hole 211 a being sufficiently wide for the passage of the coupling element 12 , which is followed by a blind hole 211 b with a contact area 211 c in circumferential direction. In the already described starting position of the needles 10 , 20 shifted to each other according to FIGS. 7 a to 7 c the coupling element 12 , 120 projects the furthest through the coupling opening 211 . If the coupling region 120 of the coupling element 12 reaching behind comes into engagement with the contact area 211 c due to an axial drive movement of the second carrier 21 the first carrier 11 is taken along and its external thread 100 is picked up by the internal thread 42 of the drive element 4 . This contact position, in which the needle tips 100 , 200 are spread apart, is shown in FIGS. 5 a , 5 b.
It has to be mentioned at this point that—in contrast to the simplified illustration in the FIGS.—the needles 10 , 20 are progressively less spread apart when spreading their needle tips 100 , 200 in direction to their fastening to the carriers 11 , 21 . With this in mind, the side views of the FIGS. 12 a , 12 b are also to be seen as schematic illustrations, which show the needles 10 , 20 and the carrier 11 , 21 in their starting position as well as in their functional position (thus with needle tips 100 , 200 spread apart).
FIG. 8 a shows the starting position with needle tips 100 , 200 moved against each other, which are nested with each other in a space-saving manner, wherein the carriers 11 , 21 rest on top of each other and the guiding bodies 31 formed at the supporting body 31 are inserted with a certain length into the guiding openings 112 , 212 . According to FIG. 8 b a slight relative movement between the needles 10 , 20 or the needle tips 100 , 200 took place what can be recognized by means of the small gap between the carriers 11 , 21 . The maximum movement between the needles 10 , 20 is shown in FIG. 8 c . Here, the axial aligned contact areas 104 , 204 are located on the same level. Simultaneously, the projections of the needle tips 100 , 200 standing on top of each other are spread apart at a maximum. The carriers 11 , 21 have now the maximum distance, which is delimited by the already described coupling opening 2011 and the coupling element 12 , 120 .
In order to prevent an undesired early engagement of the thread 43 of a drive element 4 into the thread 110 of the first carrier 11 it is recommended to provide the engagement between the guiding bodies 31 and the guiding openings 112 with sufficient friction. As an alternative, a compression spring can also be installed for this reason between the carriers 12 , 21 , wherein said compression spring can be eventually a single piece part of a carrier 11 , 21 made by injection moulding.
FIGS. 9 a to 9 c show the sleeve-shaped drive element 4 which has already been described in principle in context with the FIGS. 2 a , 2 b , enlarged in different views. It is of an advantage to produce this element out of plastic, wherein the internal thread 43 is not continuously formed but segment-like alternating to threadless free punches 44 in order to be able to guarantee in a simple manner a demoulding of a slider of an injection moulding tool. Otherwise, this part of the injection moulding tool must be elaborately unscrewed. The threadless cylindrical front region 45 of the drive element 4 serves for receiving the first carrier 11 in the starting position of the parts of the connecting device. A hexagon form-fit element 41 is provided at the rear bottom 40 for the engagement of a rotating tool.
The contrasting of the support-guiding body-combination 3 of FIGS. 10 a , 10 a and the housing of FIGS. 11 a , 11 b shall clarify the form-fit engagement of the supporting body 3 with its form-fit elements 302 into the assigned form-fit regions 502 in proximity of the edge 501 of the opening 500 in the housing 5 . The supporting area 301 of the supporting body 30 projects through the opening 500 and overlaps the front side area 50 of the housing 5 .
Another variant of needles 10 a , 20 a according to the invention is illustrated in FIGS. 13 a -13 c . The needles 10 a , 20 a are inserted into the concentric assembly holes M of the parts T 1 , T 2 to be connected, wherein the needle tips 100 a , 200 a project with their supporting areas 104 a , 204 a beyond the upper edge of part 1 . The sides of the needles 10 a , 20 a facing each other and directed inwards are nested with each other according to the notch-spring principle as shown exemplarily in the FIG. 13 b or 13 c and 13 d . In the illustrated starting position of FIG. 13 a the needle tip 200 a of the shorter needle 20 a is inserted on the back side partially “within” the longer needle 10 a . The region characterized by the dotted line shall mark the projection 201 ′ which engages into an adaptable contour of the other needle 10 a . In case of a relative movement of the two needles 10 a , 20 a , which brings the supporting areas 104 a , 204 a to the same axial level, the contours of the projections 101 ′, 201 ′ run onto each other and pivot the supporting areas 104 a , 204 a over the edge area of the assembly hole M of part T 1 .
The special feature of this embodiment is that the sum of the cross sections of the needle tips 100 a , 200 a in the plane of their supporting areas 104 a , 204 a is larger than the cross section of the assembly hole M. In the embodiment shown according to FIG. 13 c the guiding contours 106 aa and 206 aa engaging into each other form-fitted form a notch-spring system, and indeed according to the starting position of the needle tips 100 a , 200 a shown in FIG. 13 a . When moving the needles 10 a , 20 a the depth of engagement of the guiding contours 106 aa forming the notch and the guiding contours 206 aa forming the spring change as illustrated in FIG. 13 d . As a consequence, the needle tips 100 a , 200 a are pressed apart such that the supporting areas 104 a , 204 a overlap the edges of the assembly hole M. As soon as the supporting areas 104 a , 204 a have reached the same axial level the provided loading force can be transferred to the parts T 1 , T 2 to be connected by rotating the drive element 4 .
FIG. 13 e shows a further variant of guiding contours of the notch-spring principle. The contours interlocking wedge-shaped represent the starting position of the needles in analogy to the FIGS. 13 a and 13 c , thus with needle tips 100 a , 200 a moved towards each other. This wedge-shaped contour has the advantage that it is less susceptible to tolerances and is always guided centrically. The corner edges 105 a , 205 a of the supporting areas 104 a , 204 a are formed in circular section curved in this embodiment and approach thus the contour of the assembly hole M. Hereby, the size of the supporting areas 104 a , 204 a is maximized and the area pressure is minimized.
The variant illustrated in FIG. 13 b of an L-shaped cross section of back-sided contours of the needles 10 a , 20 a in the region of their tips has the advantage that one can manage with only one variant of needles.
A variant of the previously described embodiment principle of FIG. 14 which is developed extremely further to a certain extend is shown in FIG. 14 . Here, the so called depression 102 ′ in the longer needle 10 b is provided by a material reduction, in which a considerable part of the head (analogue to projection 201 ′) of the needle tip 200 b is placed. For this embodiment a sufficient pivotability of the needle tips 100 b , 200 b has to be guaranteed. When using plastic as material for the needles 100 b , 200 b the mechanical loading capacity should be improved by incorporating longitudinal fibers (preferably made of aramid or similar materials).
Finally, it still should be pointed to a variant of a connecting device (see FIGS. 15 a to 15 c ) in which only the carrier 11 a of the needle 10 a projecting the furthest is directly driven via an external thread, which is in engagement with the internal thread 43 a of the drive element. The carrier 21 a of the other needle 20 a is indeed pressed upwards by a spring F. However, the needle tips 100 a , 200 a are in engagement with each other elastically preloaded in radial direction such that these needle tips 100 a , 200 a can only then reach the same axial level with their supporting areas 104 a , 204 a if the needle tip 200 a is already in engagement with the part T 1 to be tensed and the carrier 11 a is further adjusted until it comes finally into abutment with the second carrier 21 a . When further actuating the drive element 4 the provided tension force is built up. See also the principle illustration of FIG. 15 b , where the tensing of the parts T 1 , T 2 to be connected occurs only after a longer adjustment path with mostly compressed spring F.
FIG. 15 c shows schematically the top view onto the carrier 11 a , which comprises a free punch 13 aligned radially, through which the other needle 20 a can be inserted sideways in order to join together the two needle-carrier-combinations.
LIST OF REFERENCE SIGNS
1 needle-carrier-combination
10 , 10 a , 10 b needle
11 , 11 a carrier with external thread
12 coupling element
13 free punch
100 , 100 a , 100 b needle tip/hook-shaped abutment
101 , 101 ′ projection
102 , 102 ′ depression
103 conically continuing area
104 , 104 a , 104 b holding area/supporting area
105 a corner edge of the supporting area
106 a , 106 aa guiding contour/form-fit element
110 thread
111 passage opening
112 guiding opening
120 coupling region (overlapping)
121 connecting region
2 needle-carrier-combination
20 , 20 a , 20 b needle
21 , 21 a carrier with external threat
200 , 200 a , 200 b needle tip/hook-shaped abutment
201 , 201 ′ projection
202 depression
203 conically continuing area
204 , 204 a , 204 b holding area/supporting area
205 a corner edge of the supporting area
206 a , 206 aa guiding contour/form-fit element
210 thread
211 coupling opening
211 a round hole
211 b pocket hole
211 c contact area
212 guiding opening
3 support-guiding body-combination
30 supporting body
31 guiding body
300 opening
301 supporting area
302 form-fit elements
4 drive element/thread sleeve
40 bottom
41 tool interface/form-fit element/hexagon element
42 cylindrical external area of the thread sleeve
43 , 43 a internal thread segment
44 free punch (for deforming the slider of an injection tool)
45 cylindrical area without thread
5 housing
50 front side area 50
51 form-fit region
52 external wall
500 opening, front side
501 edge of the opening 500
502 form-fit region
503 latching element
510 opening
F spring
M assembly hole
T 1 part 1
T 2 part 2 | The invention relates to a device to connect two parts, which is characterized by at least two needles which are connected on a base side to separate carriers, of which at least one carrier is operatively connected to the drive element for adjusting the needles, wherein in an initial position of the needles the needle tip are axially displaced with respect to one another and in a bracing position the needle tips are opposite one another in such a way that the supporting areas thereof are situated at the same axial level. The needles have in the region of their tips relative to their mutually facing areas integrated elevations and depressions in order to thereby control the spreading of the needle tips when the needles are actually displaced with respect to one another. | 1 |
BACKGROUND OF THE INVENTION
The present invention is directed to windmills and, in particular, to means for controlling turbine-blade pitch.
Cost and efficiency considerations dictate that windmill parts should be as light in weight as possible. On the other hand, the need to withstand wind stresses requires that the windmill parts be relatively massive. In order to reduce mass, therefore, windmills have been designed to minimize the stress experienced by the structure in response to expected wind force.
One way to reduce blade stress is to incline the blades slightly forward along the axis of rotation, i.e. in the wind direction. The centrifugal force experienced by the blades during turbine spin thus partly counteracts the wind force, which tends to bend the blades in the forward direction. This expedient, however, depends on a proper orientation of the windmill with respect to the wind direction. Specifically, this stress reduction provided by inclination of the blades depends on the degree to which the axis of rotation is aligned with the wind direction.
Although the windmill turbine is free to rotate to align itself with the wind, I have found that windmill turbines do not always respond quickly enough to sudden wind changes to maintain the desired alignment, and excessive blade stress can therefore result. Under such stress, blades may be damaged at their roots, or their tips may be bent back (downwind) and strike the tower.
It is an object of the present invention to reduce the likelihood that sudden wind shifts will enable the wind to apply a force to the blades in such a direction that the centrifugal force does not counteract the wind force.
SUMMARY OF THE INVENTION
The foregoing and related objects are achieved in a windmill mounted on a support structure so that it can pivot to face into the wind. A turbine is mounted on the chassis and includes a turbine shaft and turbine blades extending outward from the shaft. The turbine is mounted to rotate with respect to the chassis about the shaft axis, and the chassis and the turbine are together aerodynamically arranged so that the chassis normally pivots into an orientation in which the axis of the shaft is approximately parallel to the wind direction and a front end of the chassis faces into the wind. The blades can be pivoted about their longitudinal axes between active positions, in which the blades experience a relatively high wind force, and a feathered position, in which the wind force experienced by the blades is substantially at a minimum.
According to the present invention, the windmill further includes a wind vane mounted on the chassis to rotate with respect to it in a plane substantially parallel to the plane in which the chassis pivots. As a result, the wind vane indicates the angle of the wind with respect to the axis of the turbine shaft. A pitch-control mechanism monitors the angle between the directions of the wind vane and the turbine shaft and adjusts the turbine blades to their feathered positions when that angle exceeds a predetermined maximum.
Such an arrangement is particularly beneficial in a windmill whose blades are inclined rearward from a plane perpendicular to the axis of the shaft.
BRIEF DESCRIPTION OF THE DRAWINGS
These and further features and advantages of the present invention are described in connection with the accompanying drawings, in which:
FIG. 1 is a simplified perspective view of a windmill embodying the present invention; and
FIG. 2 is a block diagram of a control system employed in an exemplary embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 depicts a windmill 10 mounted on a tower 11 that supports the windmill above the ground. A windmill chassis 12 is pivotably mounted at 14 to assume an orientation in which its front end, or bow, 15 is pointed into the wind. The wind direction is indicated by an arrow 16.
A wind turbine 18 includes a number of blades 20 that are mounted on a turbine shaft 22 rotatably mounted in the windmill chassis 12 to drive an internal generator not shown in the drawings. The blades 20 extend in an approximately radial direction from the shaft 22 but are inclined slightly rearward--i.e., in the ordinarily downwind direction--from the normal to the shaft 22. This inclination reduces stress on the blades; the wind applies a force to the blades to bend them in the downwind direction, and the centrifugal force of the resultant spinning includes an upwind component, when the blades are inclined downwind, that counteracts the downwind bending. This beneficial effect follows only if the wind is coming generally from the bow, though; wind whose velocity is in a direction opposite that indicated by the arrow 16 applies a force that is not counteracted by the centrifugal force and, in fact, is aided by it.
The windmill chassis 12 includes windmill equipment of the type illustrated, for example, in U.S. patent application Ser. No. 282,965, filed on July 13, 1981, by Chertok et al. for a Windpower System. Such equipment includes a generator powered by the spinning turbine. There might also be apparatus for receiving instructions from a remote location.
The interior equipment also includes a pitch controller for controlling the pitch of the blades 20. When the windmill is turned off, the pitch controller typically feathers the blades; i.e., it orients them about their longitudinal axes to such an angle that the wind causes no appreciable spinning and its force on the blades 20 is at a minimum.
In accordance with the present invention, a wind vane 24 is pivotably mounted at 26 on the windmill chassis 12 so as to point in the wind direction. Normally, therefore, the wind vane 24 is oriented parallel to the axis of the shaft 22. However, since the windmill must include a considerable amount of equipment and thus has a relatively high moment of inertia about its pivotal axis, it is not as responsive to changes in wind direction as is the wind vane 24, whose only function is to indicate wind direction. Consequently, during changes in wind direction, the orientation of the wind vane 24 is a better indicator of the direction of wind velocity than is the orientation of the chassis 12 of the windmill. It is thus the function of the wind vane 24 to indicate the angle between the wind and the direction in which the windmill is pointing.
When that angle is below a predetermined maximum, say 45°, the windmill operates in its conventional manner. When that maximum is exceeded, though, a sensor not shown in FIG. 1 causes the windmill's pitch-control mechanism to feather the turbine 18 and thus minimize the wind force experienced by the windmill.
One of the ways to control blade pitch in response to the relative position of the wind vane 24 is depicted in FIG. 2, which is a block diagram of a system that is an adaptation of part of the pitch controller of the windmill described in the above-mentioned Chertok et al. application, which is hereby incorporated by reference.
An angle sensor 26 in FIG. 2 transmits signals containing information regarding the orientation of the wind vane 24 with respect to the windmill chassis 12. The angle sensor 24 may be any one of various sensors commonly used for similar purposes and can range from simple limit switches to synchros or other types of angle-sensing devices.
In the Chertok et al. windmill, blade pitch is controlled by an actuating rod that extends coaxially within the turbine shaft and rotates with it but is axially movable with respect to it. The pitch of the blades varies with the axial position of the actuating rod, and the actuating rod threadedly engages an actuating nut that can be rotated with respect to the turbine shaft. Therefore, the actuating rod moves axially with respect to the shaft if there is relative rotation between the shaft and the nut. The blade pitch then remains the same so long as the actuating nut spins at the same rate as the shaft does.
In order to maintain a given pitch, therefore, a clutch, represented in FIG. 2 by block 28, acts between the turbine shaft and the actuating nut so that they spin together while the clutch is activated. In order to feather the blades, the actuating nut must rotate in a direction opposite that of the shaft rotation so that the threaded engagement will cause the rod to advance axially and thus decrease the pitch. The Chertok et al. arrangement includes a servomotor for this purpose, represented in FIG. 2 by block 30, that can rotate the actuating nut at a rate higher than that of the turbine shaft in the same direction, or at some speed in the opposite direction. To feather the blades, the clutch 28 is released, and the motor drives the nut in a direction opposite to that of the shaft until the desired pitch is achieved. When the desired pitch is achieved, the clutch 28 is reengaged.
A pitch change to increase power can be achieved by releasing clutch 28 and driving the nut in the same direction as, but faster than, the turbine drive shaft.
The Chertok et al. arrangement also includes a brake, represented in FIG. 2 by block 32, that can be operated to stop the operating nut completely and thus rotate the blades to their fully feathered positions. Like the clutch, the brake is wired to fail safe: power is normally applied to it, keeping it in its released state, but if there is a power failure, the clutch 28 is released, and the brake 32 is applied to feather the blades.
The clutch 28, the servomotor 30, and the brake 32 are all controlled by a microprocessor 34 that typically monitors the rotational speed of the turbine shaft 22 and receives commands from remote locations. In response to speed information and these commands, it controls the pitch of the blades 20 in accordance with stored routines.
In order to carry out the teachings of the present invention, the microprocessor 34 can also be programmed to respond to signals from the angle sensor 26 and to operate appropriate combinations of the clutch 28, the servomotor 30, and the brake 32 to feather the turbine 18 when the angle between the windmill and the wind is greater than a predetermined maximum. The predetermined maximum can be a fixed value or, for example, a function of wind speed; specifically, it may be desired for greater angles to be tolerated when the wind speed is relatively low.
In the alternative, the angle sensor 26 can be employed merely to remove power from the control system and thus automatically disengage the clutch 28 and apply the brake 32. The sensor would thus take advantage of the failsafe arrangement of the pitch-control system.
In operation, the internal controls, not shown in the drawings, may receive a command from a remote location to begin operation. If the relative angle detected by sensor 26 is below the predetermined maximum, the result of this command is an adjustment of the blade pitch from the feather pitch position, which is the normal pitch when the windmill is not in operation, to a start-up pitch. If the angle between the wind and the windmill exceeds the maximum, on the other hand, the angle sensor 26 will prevent adjustment of the blade pitch to its start-up value. This result is only temporary, though, because the misalignment of the windmill with the wind will only be sustained if the wind velocity is too low to be useful. As the wind velocity increases, the chassis 12 of the windmill will align with the wind, the angle sensor 26 will permit the start-up pitch, and operation can begin.
As the wind velocity increases, the force on the turbine blades 20 increases, but the speed of rotation also increases, thus increasing the countervailing centrifugal force tending to prevent downwind bending.
It is possible, however, for the wind to shift too quickly for the windmill to slew around fast enough in response. In this situation, the wind can come from behind the windmill, tending to bend the windmill blades 20 toward the bow and thus cause the centrifugal force to add to, rather than subtract from, the bending force of the wind. Since the design of the blades 20 is based on the assumption that the centrifugal force will counteract the bending force of the wind, the force on the blades can be excessive if they are not feathered immediately. Since the wind vane 24 immediately senses the change in wind direction relative to the windmill housing, the angle sensor 26 causes the microprocessor 34 to release the clutch 28 and apply the brake 32, and the turbine blades 20 are thus feathered. Alternatively, the servomotor 30 can be used to feather the blades. The result is that the force experienced by the blades as a result of the wind is greatly diminished, and excessive strains are avoided.
Eventually, the chassis 12 of the windmill will realign itself with the wind, and the angle sensor 26 will sense this realignment and send a signal to the microprocessor 34 indicating the realignment. The microprocessor will then operate servo motor 30 to adjust the blades to the desired pitch, which will then be maintained by the clutch 28.
It is apparent that the present invention decreases the likelihood of excessive stress caused by misalignment between the wind and the windmill and thus allows the windmill designer to use lighter blades and thus a lighter turbine hub. | A windmill employs a separate wind vane pivotably mounted on the chassis of the windmill. An internal sensor detects the relative angle between the wind vane and the windmill and activates the pitch-control mechanism of the windmill to feather the windmill blades whenever the angle exceeds a predetermined maximum. | 8 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional Patent Application Ser. No. 60/545,479, filed Feb. 19, 2004.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates generally to window shades, and more specifically, window shades having educational displays.
[0004] 2. Description of the Related Art
[0005] The related art of interest describes various window shades, but does not disclose the present invention for instructing school children in various topics. There is a need for the utilization of school window shades to feature educational material to remind students and to exercise their memories. The relevant art of interest will be discussed in the order of perceived relevance to the present invention.
[0006] U.S. patent application Publication No. US 2003/0080231 A1 published on May 1, 2003, for James T. Lowder describes a retractable magnetic sheet comprising a retractable magnetic sheet on a window rod. The device is distinguishable for requiring a magnetic sheet upon which can hold magnets.
[0007] U.S. patent application Publication No. US 2003/0136528 A1 published on Jul. 24, 2003, for Steven B. Dunn describes a sun shade for vehicles comprising a vehicle window mountable device having a drum housing a flexible, weblike shade element in three different extended positions. Indicia such as a map of the United States or a surface on which to play tic-tac-toe are some examples. The apparatus is distinguishable for requiring a vehicle mountable window shade extendable in only three positions.
[0008] U.S. Pat. No. 6,070,639 issued on Jun. 6, 2000, to Harold M. Winston et al. describes a window shade assembly comprising a main opaque shade and one or more translucent shades, all on rollers, are capable of being individually drawn and retracted. The translucent shades have patterns or figures to cast patterns into the inner space. The apparatus is distinguishable for requiring multiple translucent shades.
[0009] U.S. Design Pat. No. US D475,005 S issued on May 27, 2003, to George B. Grijalva describes an ornamental vehicle window shade comprising double shades with figures of children.
[0010] The ornamental shades are distinguishable for requiring a set of two separated shades.
[0011] U.S. Design Pat. No. US D438,743 S issued on Mar. 13, 2001, to Leonard Trogolo et al. describes an ornamental decorated window shade illustrating a decorated Christmas tree with presents underneath. The ornamental window shade is distinguishable for requiring a Christmas tree decoration.
[0012] U.S. Design Pat. No. 426,738 issued on Jun. 20, 2000, to Amy Goodwin describes an ornamental design for a window shade with dashed figures of planes, boats, trains, planes, and the like. The ornamental window shade is distinguishable for requiring figures for display out a window.
[0013] U.S. Design Pat. No. Des. 415,382 issued on Oct. 19, 1999, to Patricia Walker describes a window shade ornamented with a kitten on a pile of three alphabet blocks A, B and C.
[0014] The ornamental window shade is distinguishable for requiring an animal on alphabet marked blocks.
[0015] U.S. Design Pat. No. Des. 343,323 issued on Jan. 18, 1994,to Robert L. Smith, Sr. describes a decorated window blind having slats with a figure of a clothed duck. The window blind is distinguishable for requiring an ornamental window blind having a duck figure on its slats.
[0016] U.S. Pat. No. 276,152 issued on Apr. 24, 1883, to Andrew Barrickle describes an opaque window shade having a stamped, painted or stenciled design proximate its lower edge. The window shade is distinguishable for requiring a stamped, painted or stenciled design.
[0017] U.S. Pat. No. 475,005 issued on May 17, 1892, to William N. Winfield describing an exhibiting device comprising a supporting frame having an apertured casing and a spring-roller located at the bottom edge of the casing. Two belts are concentrically wound the roller, wherein one belt extends above and the other belt extends below. The upper belt is attached to a spring-roller. A rolled sheet extends below the device. The device is distinguishable for requiring an apertured casing.
[0018] U.S. Pat. No. 1,997,484 issued on Apr. 9, 1935, to Henry H. Collins describes a decorated window shade comprising an ornamental translucent window shade decorated at its bottom. The window shade is distinguishable for requiring a translucent
[0019] U.S. Pat. No. 3,205,118 issued on Sep. 7, 1965, to Samuel Guffan describes decorative window shades comprising the insertion of a decorative sheet between pliable transparent sheets. The device is distinguishable for requiring the insertion of a decorative sheet between pliable transparent sheets.
[0020] U.S. Pat. No. 3,308,872 issued on Mar. 14, 1967, to Robert C. Smith describes an ornamental window shade comprising scenes or designs of varying colors capable of being selectively moved into exposed positions to be viewed. The device is distinguishable for requiring the window shade to be selectively moved into exposed positions to be viewed.
[0021] U.S. Pat. No. 3,430,374 issued on Mar. 4, 1969, to Robert A. Woodard describes an emergency signal for automobiles hung under the tailgate hood comprising a flexible sheet that is extended when the trunk lid is raised. The sheet has a sign that warns others in the rear that the car is disabled. The device is distinguishable for requiring a warning sign inside a car trunk for warning others when the trunk is open.
[0022] U.S. Pat. No. 3,462,867 issued on Aug. 26, 1969, to Edward E. Pinkman et al. describes an automobile visor mounted road map that can be pulled down to examine the road map. The device is distinguishable for requiring the attachment to a vehicle's rear view mirror inside the vehicle.
[0023] U.S. Pat. No. 4,907,636 issued on Mar. 13, 1990, to Terry L. Simon describes a decorative window shade comprising an inside surfaced decorative rectangular strip of wallpaper, wood fiber, vinyl, canvas, or fabric attached to the bottom region to match the decor of a room. The window shade is distinguishable for requiring a decorative strip at the bottom of a window shade.
[0024] U.S. Pat. No. 5,400,848 issued on Mar. 28, 1995, to Janet R. Gainer describes decorative window shades constructed of multiple layers of materials applied in layers to achieve translucent areas of varying thickness. The window shade is distinguishable for requiring various translucent areas of varying thickness.
[0025] U.S. Pat. No. 6,503,188 B1 issued on Jan. 7, 2003, to Joseph August describes a rollable health care display that can be attached to the end of a bed or a chair and extended upward by its cylindrical housing to reveal the visual display. The device is distinguishable for being required to attach to a bed or a chair.
[0026] United Kingdom Patent Publication No. 265,061 published on Feb. 3, 1927, for Samuel E. Snyder describes a window shade attached to a pair of rollers, wherein one roller having a flexible connection to one end of the shade. The shade is distinguishable for requiring two rollers.
[0027] None of the above inventions and patents, taken either singly or in combination, is seen to describe the instant invention as claimed. Thus a window shade with educational displays solving the aforementioned problems is desired.
SUMMARY OF THE INVENTION
[0028] The window shades with educational displays are intended to further instruct students and business persons in various topics which can be reviewed while passing by them. Illustrative examples are shades with: (1) globe and a list of seven continents for primary and intermediate grades; (2) images and identification of books, phone, sun, horse, school, stuffed chair, Teddy bear, alphabet blocks, alarm clock, tree, apple, and flowers intended for primary grades; (3) alphabetical letters such as capitals and lower case letters pictured with various articles such as ball for “B,b”; (4) a standing man with his muscles delineated for science classrooms; (5) a multiplication chart for intermediate grades listing an X in the upper right corner from the numbers 1 to 10 listed horizontally and vertically, and wherein the horizontal and vertical numbers are grouped in sets such as 3, 6, 9, to 30; and (6) a chart headed by eight words with a list of their synonyms. These images are dyed directly onto the window shades for educational purposes. Another advantage for the use of these shades is the increase in space in the classroom for posting items that must be changed regularly.
[0029] Accordingly, it is a principal object of the invention to provide window shades with educational displays.
[0030] It is another object of the invention to provide window shades with educational displays for school children in school.
[0031] It is a further object of the invention to provide window shades with education displays for personnel in a business.
[0032] Still another object of the invention is to provide window shades that can save space for educational material within the classroom.
[0033] It is an object of the invention to provide improved elements and arrangements thereof for the purposes described which is inexpensive, dependable and fully effective in accomplishing its intended purposes.
[0034] These and other objects of the present invention will become readily apparent upon further review of the following specification and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0035] FIG. 1 is a front elevational view of an instructional window shade with an educational display of a globe and a list of seven continents according to the present invention.
[0036] FIG. 2 is a front elevational view of a window shade for primary grade students showing books, phone, sun, horse, and the like.
[0037] FIG. 3 is a front elevational view of a window shade for primary grade students featuring the alphabet with articles starting with the specific letter.
[0038] FIG. 4 is a front elevational view of a window shade showing the human muscular system.
[0039] FIG. 5 is a front elevational view of a window shade for intermediate grade classrooms indicating answers in a multiplication table wherein X=1 to 10.
[0040] FIG. 6 is a front elevational view of a window shade depicting certain synonyms for student children.
[0041] Similar reference characters denote corresponding features consistently throughout the attached drawings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0042] The present invention is directed in FIGS. 1 to 6 to operable window shade displays with various educational materials directed to lower grade grammar students, high school students, college students, and business employees. A typical student classroom has many windows and shades. Therefore, instructive information in the form of pictures, numerals, grammar, and the like can be permanently dyed or lithographed on the shades.
[0043] FIG. 1 is a shade 10 based on the instruction of seven listed continents 12 and illustrating a globe 14 with a partial view of the continents. This shade 10 would instruct primary and intermediate school students.
[0044] FIG. 2 is a shade 16 picturing articles and their names such as a pile of books 18 , a telephone 20 , the sun 22 , a horse 24 , a school house 26 , a padded chair 28 , a teddy bear toy 30 , two alphabetized blocks 32 , an alarm clock 34 , a tree 36 , an apple 38 , and two flowers (roses) 40 . This tableau with descriptive titles in shade 14 is directed to aid primary school students.
[0045] FIG. 3 illustrates a window shade 42 the capitol (upper case) and lower case letters of the alphabet along with familiar objects beginning with that letter. Block 44 features an apple with the “A, a”. Block 46 shows a baseball for “B,b”. Block 48 depicts an alarm clock for “C, c”. Block 50 illustrates a drum for “D, d”. Block 52 features the earth for “E, e”. Block 54 shows fish for “F, f”. Block 56 has a traffic light with a flashing green to indicate “go” for “G, g”. Block 58 depicts a hammer for “H, h”. Block 60 shows a double-dipped ice cream cone to indicate “I, I”. Block 62 illustrates a slice of bread with either jam or jelly on it to indicate “J, j”. Block 64 features a kite for “K, k”. Block 66 shows a table lamp for “L, 1 ”. Block 68 depicts a magician's equipment such as a top hat and a wand for “M, m”. Block 70 has a walnut for a nut “N, n”. Block 72 features an octopus for “O, o”. Block 74 shows a spinet piano for “P, p”. Block 76 illustrates a crowned queen for “Q, q”. Block 78 depicts a robot man for “,R r”. Block 80 has a pair of scissors for “S, s”. Block 82 features a table telephone for “T, t”. Block 84 shows a U-shape pronged kitchen utensil for “U, u”. Block 86 illustrates a violin and fiddle for “V, v”. Block 88 depicts a windmill for “W, w”. Block 90 has a xylophone for “W, w”. Block 92 features a yo-yo article for “Y, y”. Block 94 has a zebra for “Z, z”. Thus, the alphabet has been dramatized with the capitol and lower case letters along with articles beginning with that letter.
[0046] FIG. 4 illustrates the human musculature on a window shade 96 as a male FIG. 98 depicting the pectoralis major 100 , the deltoid 102 , the biceps 104 , the serratus major 106 , the rectus abdominus 108 , the quadriceps femoris 110 , and the gastrocnemius 112 . Although other muscles are shown, these appear to be the most familiar.
[0047] FIG. 5 is a multiplication and division chart 114 on a window shade 116 for intermediate grade classrooms having an “X” in a corner and numerals radiating horizontally and vertically. For example, the student can check his/her answer to 6 times 6 as 36. Another use of this chart is for division of numbers. The instructor can also utilize this chart to save space on the blackboard.
[0048] FIG. 6 shows a chart 118 on a window shade 120 designed to provide children with synonyms to increase their knowledge of other words having the same general meaning. In space 120 , “A LOT” can have synonyms such as “Many, Loads, Masses”, and “Heaps”. In space 122 , “NICE” would mean “Pleasant, Good, Kind, Polite”, and “Kind”. In space 124 , “SAD” can imply “Depressed, Gloomy, Miserable, Cheerless”, and “Poignant”. In space 126 , “HAPPY” can mean “Content, Pleased, Glad, Joyful”, and “Blissful”. In space 128 , “SAID” can be substituted with “Speak, Utter, Declare, State” and “Shout”. In space 130 , “GOOD” can have synonyms “Fine, Excellent, Superior”, and “Wonderful”. In space 132 , “BAD” could be “Awful, Terrible, Dreadful, Appalling”, and “Dire”. In the last space 134 , “FUN” would be “Amusing, Enjoyable”and “Pleasure”.
[0049] Thus, various modes of instructional window shades have been shown to instruct school children or adults in business for improvement in their basic understanding of grammar, mathematics, human anatomy, and geography.
[0050] It is to be understood that the present invention is not limited to the embodiments described above, but encompasses any and all embodiments within the scope of the following claims. | Window shades with educational displays on their inside the room surfaces for educational or business classrooms are provided with various subject materials such as an earth globe and a list of the seven continents for school children or a human anatomy for adults in their working environment. | 4 |
FIELD OF INVENTION
The invention concerns a metallic flat gasket with at least one sealing layer with at least one port for sealing off two components from each other. Here, a sensor element is integrated in the system, such that it is protected from compression.
BACKGROUND OF THE INVENTION
Metallic sealing systems are used in the automotive industry primarily as cylinder head gaskets. Here, cylinder head gaskets are used to seal off various chambers, such as combustion chambers, coolant and lubricant openings, threaded bolts, as wells as ports for valve control parts, from each other. The requirements on these sealing systems continue to become increasingly rigorous and the recording of measurement data for characteristic parameters of the gasket appears to be desirable. Here, the measurement in the direct vicinity of the corresponding openings enables data recording that is as precise as possible. Due to these requirements on the dimensioning, sensor measurements are coming more and more to the forefront.
The teaching of DE 199 13 092 concerns a cylinder head gasket, on which a sensor device for detecting measurement values is arranged.
However, the disadvantage of the prior art is that the danger of compression of the sensor element is so great that only very robust sensors can be used.
Thus, the problem of the present invention is to devise a metallic sealing system that contains a sensor element that is protected from compression.
SUMMARY OF THE INVENTION
This problem is solved by the generic metallic flat gasket with the features of claim 1 and by the generic production method with the features of claim 20 . The additional subordinate claims present advantageous refinements. In the claims 27 and 28 , the use of the sealing system is described.
According to the invention, a metallic flat gasket with at least one sealing layer with at least one port is created, with a corresponding sensor layer relative to the ports deposited on at least one surface of the sealing layer, which consists of a compression protection layer with at least one break. Here, the compression protection layer is used to protect the sensor element from mechanical damage and consists of an incompressible material, e.g., high-hardness steel. Here, the sensor element is at least partially installed in the break of the compression protection layer.
In a preferred configuration, the sensor layer is deposited on a separate carrier layer. Thus, the deposition of the sensor layer can be performed independently of the production process of the cylinder head gasket. Simultaneously, the carrier layer can be selected in regard to an optimum adhesive bond between the sensor layer and sealing layer.
Here, the sensor layer can be arranged on one side of the cylinder head gasket facing either the cylinder head or the engine block. Likewise, it is possible for one sensor layer to be deposited on both sides. This allows the arrangement of several sensor elements on both sides of the metallic sealing system. Likewise, the carrier layer can be arranged on one side of the metallic sealing system facing either the cylinder head or the engine block.
In an advantageous refinement, the sensor element is at least partially installed in the carrier layer. Here, e.g., there can also be a break, in which the sensor element can be inserted. Likewise, the carrier layer can also have additional corresponding structures for connection elements to a measurement value detector unit, in addition to the structures for the sensor element. These structures can include lines or contacts. In a similar way, the compression protection layer can also have structures for the connection elements. The advantage of such structures is that, in addition to the sensor element itself, the connection elements can also be protected from compression.
In a preferred configuration, a thermally conductive layer is deposited on the end side of the sensor element facing away from the carrier layer. The thermal conductivity of this layer should be sufficiently high that a nearly error-free temperature measurement can be performed across this thermally conductive layer at the corresponding component. For example, a thermally conductive paste can be used as the thermally conductive layer. It is also preferable if the carrier layer, which faces the engine block and/or the cylinder head, has a high thermal conductivity value.
In a preferred configuration, a layer that protects against mechanical damage is deposited on the side of the sensor element facing away from the carrier layer. This protection layer provides improved protection against compression, and even more protection against wear and tear due to friction.
In an advantageous refinement, the carrier layer is produced from steel, aluminum, and/or other aluminum-containing materials, such as ceramics or enamels. Here, the carrier layer preferably has a layer thickness of less than 300 μm, with a layer thickness of approximately 150 μm being especially preferred.
The compression protection layer, which preferably consists of high-hardness steel, aluminum, and/or other aluminum-containing materials, such as ceramics or enamels, preferably has a layer thickness of less than 300 μm, with a layer thickness of approximately 200 μm being especially preferred. It is also preferred if the compression protection layer is electrically insulated at the end sides of the recess.
In a preferred refinement, the compression protection layer can also have a bead and/or stopper. Here, it is especially preferred if the sensor element is arranged in the direct vicinity of the bead in order to provide additional protection against compression. Likewise, it is possible for the sensor element itself to be stamped as a bead and/or stopper.
Preferably, the sensor element is selected from the group of piezoelectric, piezoresistive, capacitive, magnetic, electromagnetic, DMS [wire strain gauge], eddy current, optical fiber, and micromechanical sensors. The sensor element is preferably designed as a temperature sensor. The use of a resistor sensor as the sensor element in the flat gasket is likewise preferred. Especially preferred is the use of a PTC temperature probe as the sensor element.
According to the invention, a method for producing a single-layer or multi-layer metal gasket with a sensor element is proposed, for which initially a compression protection layer is deposited on the metal gasket with the compression protection layer having at least one break, in whose region the sensor element is attached by means of a frictional connection.
Here, thick-film techniques, such as those known from screen printing, are used as the preferred deposition technique. These techniques can produce a layer thickness of the sensor element in the range around 30 μm.
The sensor element can likewise preferably be deposited using a thin-film technique, which allows a layer thickness of the sensor element of around 1 μM to be realized. The PVD technique is used as the preferred deposition technique.
However, additional options for the frictional connection of the sensor element in the break of the compression protection layer also include conventional frictional connections, such as adhesive bonds, soldering, or locking devices.
A hardened steel, aluminum, and/or other aluminum-containing materials, such as ceramics or enamels, are preferably used for the compression protection layer and the carrier layer.
The flat gasket according to the invention can be used primarily for temperature measurements at combustion chamber openings. However, it can also be used for force, path, expansion, acceleration, and/or pressure measurements at combustion chamber openings.
BRIEF DESCRIPTION OF THE DRAWINGS
With reference to the following figures, the flat gasket according to the invention will be explained with reference to individual examples, without limiting the object according to the invention to these examples.
FIG. 1 shows a flat gasket according to the invention in cross section.
FIGS. 2–10 show various deposition variants of the sensor layer.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows a flat gasket in the form of a cylinder head gasket with a stopper 6 and two beads 7 , 7 ′. Connected here on both sides is a sensor layer 1 , 1 ′ consisting of the compression protection layers 2 , 2 ′ and the sensor elements 4 , 4 ′, which are located in a break of the compression protection layer. In this example, the sensor layer has a thickness of 270 μm. On the sides facing away from the gasket layers 8 , 8 ′, there is a carrier layer 5 , 5 ′, which is in direct contact with the cylinder head 9 or the engine block 10 [sic; 9 ′] on the sides facing away from the sensor layers. As this drawing shows, it is possible for the sensor and carrier layers to be arranged on the sides facing both the cylinder head and also the engine block. Similarly, it is also possible for a sensor layer to be deposited on only one side of the cylinder head gasket.
FIG. 2 shows the compression protection layer 11 with a break, in which the sensor element 12 is inserted. Simultaneously, this sensor layer 13 is deposited on a carrier layer 14 .
In comparison with FIG. 2 , FIG. 3 shows the application of a sensor layer 13 on a carrier layer 14 with the sensor element 12 only partially filling the recess because a thermally conductive layer and/or a layer 15 protecting against mechanical damage is also deposited on the side facing away from the carrier layer 14 .
In FIG. 4 , the sensor element 12 is designed so that it completely fills the recess of the compression protection layer 11 , and, at the same time, extends into the carrier layer 14 . Here, the carrier layer 14 has a structure, in which the sensor element 12 is inserted. A frictional connection between the carrier layer 14 and the sensor element 12 is not absolutely necessary.
In FIG. 5 , the sensor element 12 likewise extends into the carrier layer 14 with a layer 15 , which is thermally conductive or which protects against mechanical damage, also deposited on the side of the sensor element facing away from the carrier layer 14 . This layer 15 can be applied, e.g., in the form of a paste.
Analogous to FIG. 2 , FIG. 6 shows a sensor layer 13 consisting of a compression protection layer 11 with a break, in which a sensor element 12 is inserted. In this case, however, no carrier layer is deposited, so that the sensor 13 is deposited directly on the sealing layer of the cylinder head gasket.
FIG. 7 shows a sensor layer 13 consisting of a compression protection layer 11 with a break, in which a sensor element 12 is attached, which is covered on one side with a layer 15 that is thermally conductive or that protects against mechanical damage.
FIG. 8 shows a sensor layer 13 consisting of a compression protection layer 11 , with the sensor element 12 here being attached in such a way in the recess of the compression protection layer 10 [sic; 11 ], such that the sensor element 3 [sic; 12 ] is locked by means of the sensor socket 16 .
FIG. 9 illustrates a portion of a gasket 20 that includes a sealing layer 22 , a carrier layer 24 , and a compression protection layer 26 interposed between the sealing layer 22 and the carrier layer 24 . Compression protection layer 26 is defined by a break and a sensor layer 30 (not sectioned for clarity) is positioned within the break. Preferably, both compression protection layer 26 and sensor layer 30 are deposited on either sealing layer 22 or carrier layer 24 . gasket 20 also includes a bead portion 36 and a stopper portion 40 .
FIG. 10 illustrates a portion of a gasket 120 that includes a sealing layer 122 , a carrier layer 124 , and a compression protection layer 126 interposed between the sealing layer 122 and the carrier layer 124 . Compression protection layer 126 is defined by a break and a sensor layer 130 (not sectioned for clarity) is positioned within the break. Preferably, both compression protection layer 126 and sensor layer 130 are deposited on either sealing layer 122 or carrier layer 124 . The gasket 120 also includes a bead portion 136 where the sensor layer 130 is stamped as a bead. | The present invention concerns a metallic flat gasket with at least one sealing layer with at least one port, with a sensor layer corresponding to the ports being deposited on at least one surface of the sealing layer. This sensor layer consists of a compression protection layer and at least one break, in which a sensor element is at least partially installed. | 5 |
BACKGROUND OF THE INVENTION
The present invention relates to limb protection devices for amputees and, in particular, to a multi-piece, padded, fabric and fleece lined assembly for below-knee amputees, wherein a leg or thigh piece, a stump contact piece, a distal end cap cover piece and a knee or patella cover piece contain resilient contoured inserts and/or foam cushion pieces that support/brace and cushion the thigh, knee and stump end and wherein hook and loop fasteners and stabilizing straps organize and secure the pieces to each other and to the amputee's limb.
A variety of appliances have been developed for amputees for use during post-operative recovery, therapy and long term maintenance. The devices are typically constructed for particular use with the arms and legs. Some devices serve as dressings during recovery. Some devices mount to the limb to stabilize the stump end and support or cushion a prosthesis mounted to the limb. Some devices include active linkages that cooperate with and stabilize limb movement. U.S. Pat. Nos. 5,302,169; 5,529,575; 5,571,206 and 5,651,792 disclose devices having active, hinged linkage pieces adapted for use by below-knee amputees.
Some appliances are used daily after removal of a prosthesis to cover, warm and/or protect the limb and stump, such as during periods of relative inactivity (e.g. when at home or asleep). It is to the latter category that the subject invention belongs. The assembly of the present invention is intended to mount to and warm an amputated limb to promote vasodilatation, maintain blood circulation and prevent ulceration or other physical degradation of the stump. That is, by keeping the limb and stump end warm, the blood vessels don't constrict and healthy blood flow is maintained. The device also physically cushions and warms the limb with minimal skin trauma (e.g. ulcerations, cracking and/or abrasions).
The present below-knee limb protector assembly was developed to provide a multi-piece light weight assembly that warms, cushions and stabilizes the extremity. The assembly includes a thigh piece having a longitudinal support portion containing a rigid channel member constructed from a resilient and malleable material and several laterally extending cloth covered wings having fasteners that overlap to encase the limb and cooperate with associated strap fasteners. A stump contact piece, end cap piece and knee or patella cover piece contain foam pads to cushion the stump end and knee. Strips of hook and loop fastener material are arrayed about the protector pieces and judiciously overlap to contain the protector pieces to each other and the limb. Buckled straps further support the protector to the limb.
SUMMARY OF THE INVENTION
It is accordingly a primary object of the invention to provide a thermally insulated protection assembly for below-knee amputees to stabilize, cushion and warm the limb to stimulate blood circulation.
It is a further object of the invention to provide a below-knee protective assembly comprising several sewn fabric and fleece pieces having a number of hook and loop fasteners fitted to overlapping surfaces of the assembly pieces and associated straps to collectively wrap and fasten to configure and encase the protective device about the thigh.
It is a further object of the invention to provide a protective device having a thigh piece that contains a longitudinal, foam covered, contoured, resilient channel member shaped to contain and support the thigh.
It is a further object of the invention to provide a thigh support piece wherein overlapping fleece lined fabric wings contain multiple separated lines of stitching that segregate the wings to accommodate tailor fitting the assembly; presently the stitching is positioned to accommodate differing circumferential limb sizes and wherein the stitching transversely bisects each wing piece and is displaced sufficiently (e.g. 1 to 4-inches) to segment each wing and permit shortening the wing pieces adjacent the stitching without fraying to tailor the length of the wing pieces to fit the circumference of the amputee's limb.
It is a further object of the invention to provide stump contact cushions, spacers and adjoining end cap pieces that provide cloth/fleece covered foam cushions that directly contact the stump end and/or fill a space between the contact piece and an end cap piece to conform to and cushion the stump end and fasten to a limb encasing thigh piece.
It is a further object of the invention to provide a knee or patella cover support piece that contains a foam cushion and mounts to a limb encasing thigh piece.
The foregoing objects, advantages and distinctions of the invention are obtained in a presently preferred fabric covered limb protector assembly of the invention that is lined with fleece. One or more pieces can also contain a thermal insulation. Several overlapping tabs of hook and loop fastener material are arrayed about the surfaces of several wing pieces at a thigh cover piece and detachable knee and end cap fabric cover pieces and mate with other associated fastener pieces and straps. The fasteners at the wings of the thigh piece and detachable knee and end cap pieces align to define and selectively control the fitting of the protective assembly to the amputee's thigh and stump.
The thigh piece contains a longitudinal foam covered, rigid channel member constructed from a resilient and malleable material having a contoured channel that supports the posterior surface of the thigh and knee. Laterally extending wing portions extend such that the thigh piece exhibits a general “H” shape. The wing pieces include displaced lines of transverse stitching organized and arranged to permit cutting and shortening the wing pieces to fit different thigh circumferences. The length of at least one wing piece can thereby be tailored to assure a proper fit about the circumference of an amputee's thigh upon wrapping and overlapping the wing pieces onto each other.
Hook and loop fasteners are secured to external fabric and internal fleece surfaces of the assemblies' pieces and are aligned to overlap and secure the protective assembly to the amputee's thigh. Other accessory, extension pieces having tabs of hook and loop fastener material can be mounted to the thigh piece wings to extend the wings to fit amputees with large diameter thighs.
A stump cover or end cap piece contains a foam cushion and provides a fleece liner and mates to the stump end. Associated fabric/fleece covered foam spacers can be added to fill the longitudinal space of the thigh piece.
An end cap piece contains a foam cushion and wing pieces that support tabs of hook and loop fastener material and mount to the thigh piece to contain the stump cover and filler pieces to the thigh cover piece.
A fabric and fleece covered knee or patella cover piece contains a foam cushion and supporting sewn strips and straps of hook and loop fastener material that overlap and mount to the thigh piece to cover the knee.
Still other objects, advantages, distinctions and constructions of the invention will become more apparent from the following description with respect to the appended drawings. Similar components and assemblies are referred to in the various drawings with similar alphanumeric reference characters. The components can be combined in various combinations and with other limb protection assemblies. The description should therefore not be literally construed in limitation of the invention. Rather, the invention should be interpreted within the broad scope of the further appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective drawing of the leg protector assembly removed from an amputee's leg and wrapped and buckled to a closed condition with the knee and end cap pieces mounted to the leg or thigh cover piece.
FIG. 2 is a perspective drawing of the leg protector assembly folded open and showing the relative positioning of a portion of an amputee's leg to the leg or thigh cover, the knee cover, stump cover, and end cap pieces and an accessory foam filler pad that mounts between the stump cover and end cap pieces and wherein a cutaway view is shown to an internal foam cushioning and/or a possible thermal insulation/cushioning material.
FIG. 3 is a rear perspective drawing of the leg protector assembly folded open with the knee and end cap cover pieces detached, along with a detached thigh wing extension piece and wherein cutaway views depict an elongated rigid thigh channel support member and foam cushioning liners mounted in the thigh cover piece and several foam pads mounted in the knee cover, stump cover and end cap pieces.
FIG. 4 is a rear perspective drawing of the leg protector assembly folded open with the knee and end cap cover pieces attached to the thigh cover piece and wherein stump cover end cap and spacer pieces are shown removed from the assembly.
Similar structure throughout the drawings is referred to with the same alphanumeric reference numerals and/or characters.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIGS. 1-4 several perspective views are shown in various stages of assembly to the present invention of a therapeutic leg protector assembly 2 for partial leg (e.g. below-knee) amputees. The leg protector assembly 2 is constructed of several sections or pieces that assemble to form the protector 2 shown removed from a wearer's leg in a fully assembled condition in FIG. 1 . The several pieces of the protector 2 are constructed from an air permeable fabric cover material 4 . The cover material 4 is presently sewn from a durable velour cloth. Other materials such as a heavyweight cotton fabric, CORDURA® or other fabrics or laminated/layered fabric and insulation combinations might also be used.
The interior surface of the cover material 4 is lined with a fleece material 6 . A thermal insulation material 8 shown in partial cutaway at FIG. 2 , if desired, can also be mounted between the cover material 4 and the interior fleece lining 6 . A suitable thermal insulation material 8 can for example comprise THINSULATE® or any of a variety of other cushioning and insulating materials. The fleece 6 and any provided insulation material 8 collectively provide a thermal barrier to maintain the temperature of a covered limb 9 to promote dilation of the blood vessels and blood flow through the covered extremity.
The leg protector 2 when fitted to an amputated limb, such as the leg or thigh, is assembled from a number of separate pieces that are positioned to the limb and sequentially overlapped and fastened or attached to each other. When fully assembled the protector 2 covers, warms and protects the amputee's limb.
With attention to FIG. 2 and during fitting, an elongated, “H-shaped” leg or thigh piece 10 is typically laid out and the wearer's limb 9 is aligned to lie in a longitudinal center portion that defines a channel or trough space 11 . The trough space 11 exhibits a contoured curvature (e.g. arcuate) when viewed end on. The curvature is defined by a resiliently rigid, generally “U-shaped” channel or trough member 12 contained in the longitudinal center portion of the thigh piece 10 , see FIG. 3 . Prior to mounting the protector assembly 2 , the limb 9 can be wrapped with a gauze material or other suitable cover or sock 7 can be mounted to the limb.
The channel member 12 extends substantially the length of the thigh piece 10 . The channel member 12 is presently constructed of a resilient plastic material. The material is generally rigid but can flex laterally and torsionally without breaking. A variety of different plastics, KEVLAR®, polymers, compositions or metal materials can be used to form the channel member 12 . The contour of the channel shape might also be adjusted depending upon the limb and for example might be molded or formed into a preferred shape prior to or after mounting in the thigh piece 10 . Depending upon the material, heat or other external energy sources can be used to tailor contour the channel space 11 .
One or both of the posterior and anterior surfaces of the channel member 12 can be covered with a layer of foam 14 . The channel member 12 mounts in a longitudinal pocket defined by lines of stitching formed between the cover and fleece liner materials 4 and 6 . The limb 9 (e.g. leg or thigh) of an amputee when fitted to the thigh piece 10 nests in the curvature of the channel space 11 and the internal fleece lining 6 and underlying foam layer 14 conform about the limb 9 . The thigh and knee are simultaneously supported in coaxial alignment with the channel space 11 and the knee is generally immobilized.
Once the thigh and knee are fitted into the thigh piece 10 a space can exist at the end of the amputee's stump. A stump contact cover piece 20 is then positioned in the space to contact the distal or stump end of the limb. The stump cover piece 20 provides a fabric cover 22 and fleece liner 24 that are sewn together to contain a generally cylindrical foam pad 26 . The fleece end 24 is mounted to contact the stump end. Depending upon the length of the limb relative to the thigh piece 10 , one or more cloth covered foam filler pieces 26 can be mounted distal to the stump contact cover piece 20 , see FIG. 4 .
An end cap piece 30 having a fabric cover 32 and fleece lining 34 and containing a foam pad 36 is next fastened to the thigh cover piece 10 . Tabs of hook and loop fastener material 38 and 40 that are adhered or affixed such as by sewing to the fleece lining 34 and fabric cover material 4 of the thigh piece 10 are overlapped and fastened together to hinge the end cap piece 30 to the thigh piece 10 . The end cap piece 30 can thereby pivot relative to the distal end of the thigh piece 10 to align the foam pad 36 of the end cap 30 with the stump cover piece 20 and any filler pieces 26 .
A tongue portion 42 extends from the end cap piece 30 and independently folds to mount over the anterior surface of the contained limb 9 and stump cover piece 20 . Wings or straps 43 of hook fastener material 38 laterally extend from the end cap piece 30 and separately attach to longitudinal tabs of loop fastener material 40 attached to external sides of the thigh piece 10 . Upon folding the tongue 42 over the stump end and stump cover 20 and securing the fastener straps 43 to the thigh piece 10 , the stump contact piece 20 and filler pieces 26 are held in place.
The remainder of the limb protector pieces are next arranged and secured to each other to fully secure the protector assembly 2 to the amputee's limb. The thigh piece 10 is secured to the limb and end cap piece 30 with upper and lower wing or arm portions 50 and 52 and 54 and 56 that extend from longitudinal sides of the thigh piece 10 . The relatively short side arm portions 52 and 56 extend approximately 1 to 2-inches and contain tabs of appropriate hook/loop fastener material 38 or 40 sewn to the fleece lining 6 .
The relatively longer upper arm portions 50 and 54 are constructed to lengths on the order of 8 to 14-inches to accommodate thighs of differing circumference. The arm portions 50 and 54 include displaced lines of sewn stitching 60 that segment and define a series of tabs 62 at each arm portion 50 and 54 . A tab 62 can be severed from the thigh piece 12 by cutting between the lines of stitching 60 or in other fashions without producing fraying at the severed edges. The paired lines of stitching 60 separate the wing arms 50 and 54 into several tabs 62 and each tab sized in a range of approximately 2 to 4 inches in length. Depending upon the amputee, one or more tabs 62 can be severed to tailor fit the length of the wings 50 and 54 to the circumference of the bound limb. The extraneous tabs 62 are severed at or between the stitching lines 60 without fraying or separation of the fabric and fleece layers 4 and 6 . It is to be appreciated single lines of stitching 60 might also be used to accommodate tailor fitting.
Upon wrapping the wing arms 52 and 56 over the limb and overlapping the arms 52 and 56 with the arms 50 and 54 , tabs of appropriate hook/loop fastener material 38 or 40 sewn to the fabric cover material 4 and fleece lining 6 at the arms 52 and 56 mate with the fastener tabs at the arms 50 and 54 to secure the thigh piece 8 to the limb 9 . The overlapped arms 52 and 56 also bind the tongue portion 42 of the end cap piece 30 to the limb.
One or more fabric 4 and fleece 6 covered wing extension pieces 64 (one of which is shown at FIG. 3 ) can be fastened to the arms 50 - 56 to appropriately extend the length of the overlapping combined arm pieces 50 , 52 and 54 , 56 to fit amputees having thighs of large circumferences.
The protector assembly 2 is further secured to an amputee's limb by additionally wrapping buckled straps 70 sewn to the cover material 4 at the wing arms 50 - 56 to independently overlap the fastened wing arms 50 - 56 . Mating buckles 72 and 74 sewn to the ends of the straps 70 are then fastened to securely attach the thigh piece 10 to the amputee's limb, see FIG. 1 . A variety of different types of mating buckles and fasteners can be used to secure the ends of the straps 70 .
A knee or patella cover piece 80 is next affixed to the thigh piece 10 . The knee cover piece 80 comprises an envelope of fabric 4 and fleece 6 material that contain a foam cushion piece 82 . Straps 84 extend from the fabric cover material 4 and support tabs of hook/loop fastener material 38 and/or 40 . The knee cover piece 80 is mounted over the wrapped thigh cover 10 to cover the amputee's knee and the straps 84 are secured to the longitudinal tabs of hook/loop fastener material 38 and/or 40 that extend along the sides of the thigh piece 10 .
While the invention has been described with respect to a number of preferred constructions and considered improvements or alternatives thereto, still other constructions may be suggested to those skilled in the art. It is also to be appreciated that selected ones of the foregoing features can also be used singularly or be arranged in different combinations to provide a variety of improved therapeutic limb wear. The foregoing description should therefore be construed to include all those embodiments within the spirit and scope of the following claims. | A multi-piece therapeutic cover that assembles to warm, cushion and stabilize the thigh of a below-knee amputee. A thigh piece contains a resiliently rigid channel piece and several laterally extending, wings including sizing tabs that overlap and cooperate with associated straps. A stump contact piece, end cap piece and knee cover piece contain foam pads to cushion the stump end and knee. Strips of hook and loop fastener material arrayed about the surfaces of the protector pieces judiciously overlap to contain the protector pieces to each other and the limb. Buckled straps further support the protector assembly to the limb. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority from provisional application No. 60/943,635 filed Jun. 13, 2007.
ORGIN OF THE INVENTION
[0002] The invention described herein was made by employees of the United States Government and may be manufactured and used by or for the Government for governmental purposes without payment of any royalties thereon or therefor.
BACKGROUND OF THE INVENTION
[0003] 1. Field of the Invention
[0004] This disclosure relates to computer technology for implementing computational fluid dynamics analysis.
[0005] 2. Description of the Related Art
[0006] Computational fluid dynamics (CFD) analysis is a complex technology involving strongly coupled non-linear partial differential equations which perform computations in a finite difference form supported by a discrete grid domain containing complex geometric shapes.
[0007] CFD analysis is often applied to flows typical of aerospace systems. Such flows often are characterized by the Mach number, which may range from 0 to 25. Such flows often have high Reynolds numbers resulting in regions of laminar flow becoming turbulent flow. Boundary layers are created by flows along body and inlet surfaces. Internal flows may have adverse pressure gradients. Shock waves, accompanied by separation of the boundary layer, may be present at transonic, supersonic and hypersonic speeds. Real gas effects may become important at hypersonic Mach numbers. The geometry of the system may be complex and unsteady flow may be present.
[0008] The efficacy of the CFD analysis depends on the manner of subdivision of the three-dimensional space. The numerical approximation of the Navier-Stokes equation contains errors that depend on the local density of tetrahedral subdivision and the local flow situation. Often times, deficiency of density distribution in the space is known only after the completion of a CFD analysis. Practitioners of the art have long desired to have an accurate, fast, and robust tool to modify the grid by h-refinement or some other means. However, modern computational mesh may contain more than 100 million cells. It is a monumental task for practitioners of the art to analyze both the solution and the mesh to decide where and how to perform mesh refinement efficiently within a reasonable amount of time and with a reasonable amount of effort.
[0009] Another impediment to applying the h-refinement procedure for advanced CFD analysis is that the conventional method of refinement subdivides each targeted cell into eight parts. Should refinement be required again at the location of the original cell, two steps of division would result in 64 parts, an unwieldy number. To make matters worse, the rules for grid integrity would require the subdivision of neighboring cells into eight, four, or two parts at each step of h-refinement.
[0010] The foregoing examples of the related art and limitations related therewith are intended to be illustrative and not exclusive. Other limitations of the related art will become apparent to those of skill in the art upon a reading of the specification and a study of the drawings.
[0011] Embodiments of the present disclosure meet the long-felt need for an accurate, fast, and robust tool to modify the grid by h-refinement.
SUMMARY OF THE INVENTION
[0012] In accordance with the present invention, a naturally occurring structure is recognized for the first time to facilitate cell subdivision into only two parts at each step. This naturally occurring structure has been termed herein a “pinwheel” and is comprised of a group of neighboring cells sharing only one common edge (as explained more fully below). At each h-refinement step, all cells in a pinwheel are partitioned each into two pas, with this partitioning occurring in preferred directions selected by the CFD practitioner. For example, the practitioner may choose directions with the highest local gradient of a flow quantity. Additionally, in accordance with the present invention, such subdivision of each pinwheel does not propagate to contiguous cells or pinwheels. This feature maintains grid integrity. Only the cells meeting desirable requirements of the CFD practitioner are divided, achieving the highest degree of functionality and having the economy of adding the least number of cells at each step. The pinwheel representation of the tetrahedral grid domain is complete and exhaustive because a pinwheel is associated with each edge, and edges are wherever a tetrahedral cell exists in the grid domain.
[0013] Additionally, the present invention will permit the practitioner to break up the large cells multiple times by repeated applications of this adaptive process.
[0014] Such embodiments of the present invention provide the benefit of robustness, economy of minimum cell addition, and very fast run time for user directed grid enrichment and flow solution adaptive grid refinement.
[0015] The following embodiments and aspects thereof are described and illustrated in conjunction with systems, tool, and methods which are meant to be exemplary and illustrative, not limiting in scope. In various embodiments, one or more of the above-described problems have been reduced or eliminated, while other embodiments are directed to other improvements, as will be apparent to those of skill in the art upon a reading of the specification and a study of the drawings.
[0016] The novel abilities and features of the embodiments of the present invention can also include placing the flow functions (e.g., flow quantity, pressure, velocity, turbulence, etc.) in the inventive code for instant access by the user, as well as allowing the user to select the function values or gradients to suit their particular applications without hindrance because the function set can contain all common CFD physical functions represented by the Navier-Stokes equation.
[0017] In accordance with the present invention, innovative numerical filtering algorithms are used in embodiments of the code to relieve the practitioner of the art from the time-consuming chores of performing calculations of statistical distribution of the flow function and then setting the h-refinement threshold amongst millions of tetrahedral cells. The fast and compact algorithms that are critical to the success of the h-refinement process do not exist outside of the inventive embodiments. The present invention automatically determines the adaptation numerical threshold for the selected flow function(s). For example, the practitioner may simply request to divide a certain percentage of the eligible cells (e.g., the top five percent), and the inventive code will automatically determine the correct numerical threshold for adaptation (or division) for the chosen function(s).
[0018] Embodiments of the present invention create a unique relational database for quickly identifying the edges and cells for division. The cell division process will not be efficient or robust without this unique relational database. This database recognizes a structure in the tetrahedral unstructured mesh, herein termed a “pinwheel.”
[0019] In the edge selection process based on the functions selected by the practitioners of the art, only the pole-edge (as defined and explained below) will be divided if the functional value within a pinwheel exceeds the threshold for adaptation (and this pinwheel is chosen for division). As a result, all selected cells are divided into only two, not four or eight as in other known methods which do not recognize the pinwheel structure in the tetrahedrons unstructured mesh.
[0020] Dividing a cell by only a factor of two has tremendous significance in practical applications of h-refinement. It allows the practitioners of the art to perform repeated adaptation without a huge increase in the final size of the computational grid, and the cells are divided only in regions where such division is warranted because the division does not propagate to the pinwheel's neighbors.
[0021] In addition to the exemplary aspects and embodiments described above, further aspects and embodiments of the present invention will become apparent by reference to the drawings and by study of the following descriptions.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] FIG. 1 is a flow chart of one embodiment showing the steps involved in generating the grid files for user applications.
[0023] FIG. 2 is a diagrammatic depiction of a pinwheel containing seven tetrahedrons.
[0024] FIG. 3 is a diagrammatic depiction of the division of an edge of a tetrahedron resulting in two new tetrahedrons.
[0025] FIG. 4 is a flow chart showing the databases and tables included in step 16 in FIG. 1 .
[0026] FIG. 5 is a flow chart showing the steps included in steps 22 and 24 in FIG. 1 .
DETAILED DESCRIPTION OF THE INVENTION
[0027] In embodiments of the present disclosure, the following terms have the indicated meanings. “Tetrahedral Cell” means a volume element in space bound by four vertices, six edges, and four triangular surfaces. “Tetrahedral Unstructured Grid” means a discretization of a three-dimensional volume of space in which the elementary units are tetrahedral cells. The organization of the tetrahedral cells in the grid follows a strict set of geometrical rules. “h-refinement” means a grid refinement by dividing existing cells into two, four, eight cells of the same geometric type, for example, tetrahedrons. “Pinwheel” means a feature in the tetrahedral mesh formed by all cells attached to a single edge (see FIG. 2 ). “Pole-edge” means the common edge for all the cells in a pinwheel.
[0028] Embodiments of the present invention have been written in standard Fortran-90 language. They can be complied and run on any Unix or Linux computer platform. Embodiments also can be adapted to run on a personal computer (PC) platform if desirable, or can be written in other languages, or for other platforms. Two versions of the code using different methodologies have been written to ensure reliable operation.
[0029] The novel features of the present code can include a very large collection of user selectable options, a very fast execution time with run time almost linearly scalable to the number of cells in the grid by construction of a unique internal database, the utilization of the pinwheel structure for cell partition into only two parts and without propagation of cell division outside of the pinwheel, grid integrity requirements being automatically satisfied (i.e., the known rules of grid integrity); an easy to understand syntax with input on the command line; and automation of grid modification, after preliminary CFD solutions are obtained.
[0030] FIG. 1 is a flow chart of one embodiment of the present invention showing the steps involved in generating the grid files for user applications.
[0031] In step 10 the user begins by choosing one of the three main branches of the code for adding grid. That is to say, the user chooses to add grid either according to a given list of cells, or in prescribed spatial domains, or by adaptive addition of cells according to flow functions. The implementation of the third option, the adaptive addition of cells according to flow function, includes all the steps in FIG. 1 .
[0032] In step 12 the user indicated groups of files for grid geometry and solutions are transferred to computer memory.
[0033] In step 14 , the original grid database integrity according to established rules for grid connectivity between points, edges, and cells are verified.
[0034] In step 16 , innovative internal relational databases (e.g., tables) for accurate and fast execution of h-refinement according to user instructions are created. The creation, utilization, and the completeness of these internal relational databases are unique to the present invention (see FIG. 4 , and its description below, for further details of these tables.).
[0035] In step 18 , the user instructions are decoded and organized according to easy-to-use and easy-to-remember syntax. A to-do list is generated for performing the requested h-refinement.
[0036] In step 20 , user requested flow variables from the five (expandable to seven or more, depending on physical composition of the fluid) primitive variables in the flow solution (however, other combinations can also be derived) are generated. Values of flow variables are associated with each cell, which are in turn transferable to edges and points in the grid.
[0037] In step 22 flow variable and gradient statistics for the values of each function are calculated and set an adaptation threshold for all cells and edges. (see, FIG. 5 and its description below, for additional details)
[0038] In step 24 all the edges in the grid are examined and all edges which have functional values exceeding the threshold are marked. Within a small neighborhood of contiguous cells, the highest ranked marked edge is chosen as a “pole edge” around which a pin wheel is defined (and any other marked edges in the pinwheel are now “unmarked”). This is done repeatedly in the process until all qualified edges are exhausted (see, FIG. 5 and its description below, for further details).
[0039] In step 26 all cells with one marked edge (the pole edges) are marked for division.
[0040] In step 28 each marked cell is divided by two.
[0041] In step 30 a new database is created for the adapted grid and the database is checked for integrity according to the same rules as in step 14 .
[0042] In step 32 the new grid is written into a set of files.
[0043] In step 34 the user is provided a summary of the results, for example, the statistics of the process, a new grid, and a new solution file with data corresponding to the new grid. If desired, the user can perform repeated adaptation from step 12 to further divide cells using the new grid and the new solution.
[0044] It should be noted that if in step 10 the user chooses to add grid either according to a given list of cells, or in prescribed spatial domains (rather than by adaptive addition of cells according to flow functions) then only steps 10 , 12 , 16 , 30 , 32 and 34 would apply.
[0045] FIG. 2 is a diagrammatic depiction of a pinwheel containing seven tetrahedron cells. The tetrahedrons represented are described by the lettered points; ABCD, ABDE, ABEF,ABFG, ABGH, ABHK, and ABKC. Division of the edge AB by midpoint M results in the division of each tetrahedron into two tetrahedrons.
[0046] FIG. 3 is a diagrammatic depiction of the division of an edge of a tetrahedron cell resulting in two new tetrahedron cells. Edge AB is divided into by mid-point M. The original tetrahedron ABCD is thereby divided into smaller tetrahedrons AMCD and MBCD.
[0047] FIG. 4 is a flow chart showing the databases and tables included in step 16 in FIG. 1 . These four tables are linearly scalable and form the core of the internal high-speed search engine. In the original grid file, point and cell identities are sequential numbers determined as parts of the original grid generation process. In the embodiments of this software, each edge is given a unique identity number. Three tables are created to represent a complete relational databases to link points to edges, edges to cells, cells to edges, and edges to points
[0048] Box 162 entitled Cell-to-Points is a table of the original grid files.
[0049] Box 164 entitled Point-Pairs-to-Edge is a database arranged in sequential order. Each cell has six edges, and each edge has two end points. Each edge has a higher and a lower end-point identification number. The sequential order arrangement uses the higher number first, and then the lower number. In a first pass of the edge identification process, the embodiments count the numbers of edges having the same higher point number, and assigns sufficient space to accommodate all such edges in the edge table. In a second pass, all edges with the same high identification number are placed as a group within the assigned space in order of appearance into the table, the table item number for each edge becomes the unique identification number of each edge.
[0050] Box 166 entitled Edges-to-Cell is a table which allows quick search of pinwheels by the process of two steps. The first step creates a list of cell identification numbers in which all cell identifications related to a given edge are placed contiguously in the list. The second step creates a table of location keys and the number of attached cells for each edge. When the inventive code selects an edge and then needs to know all of the cells attached to it, the table can instantly provide the location of the cell group and provide all the cell identification numbers related to this edge.
[0051] Box 168 entitled Cells-to-Edges identifies the six edges of each cell which allows quick processing. The cells-to-edges table is novel to the disclosed inventive process. This new table, arranged in the order of the cell identity numbers, provides the identities of the six edges of each cell. The cell-to-edges-table facilitates instant access whenever the grid adaptation process requires such information for a cell. The four tables (cells-to-point, point-pairs-to-edges, edges-to-cells, and cells-to-edges) utilized together is a novel feature for providing a complete roadmap for the present invention.
[0052] FIG. 5 is a flow chart showing the substeps included in steps 22 and 24 in FIG. 1 . Within step 22 the following substeps are performed: in substep 220 , the practioner chooses one or more desired function that he or she wishes to analyze, for example, pressure, velocity, turbulence, etc; in substep 222 hundreds of numerical bins are assigned to each function, between the maximum and minimum value of each function; in substep 224 the code calculates a function value for each edge and assigns each edge to the corresponding bin. The process proceeds by scanning through all the bins and counting the number of occurrences for the function value(s) belonging to each bin. A threshold is set to select, in accordance with specifications by the user of this software, a percentage of the total number of edges that bear significant function values (e.g., excluding constant values in regions representing by background flow properties, and other similar situations) In subset 226 , the inventive code determines the bins that contain edges that are above the threshold value and confers a rank on the edges, for example, between 1 through 16 according to how much the edge values have exceeded the threshold.
[0053] Substeps 224 and 226 are repeated through all the functions selected by the users in each application of this software. When an edge is qualified for adaptation under more than one function, the higher ranking amongst all qualifying functions is given to this edge.
[0054] Within step 24 the following substeps are performed: in substep 242 all edges selected for adaptation are marked in the grid; in subset 244 , from a small neighborhood of contiguous cells the highest ranked marked edge is chosen as a “pole edge” around which a pinwheel is defined. This is done repeatedly in the process until all qualified edges in the entire grid are exhausted. In substep 246 only one highest ranking edge (the “pole edge”) in each pinwheel is retained as marked for cell division, i.e., any other marked edge in a pinwheel is no longer “marked.”
[0055] While a number of exemplary aspects and embodiments have been discussed above, those of skill in the art will recognize certain modifications, permutations, additions, and sub-combinations thereof. It is therefore intended that the following appended claims and claims hereafter introduced are interpreted to include all such modifications, permutations, additions, and sub-combinations as are within their true spirit and scope. | An exemplary embodiment providing one or more improvements includes software which is robust, efficient, and has a very fast run time for user directed grid enrichment and flow solution adaptive grid refinement. All user selectable options (e.g., the choice of functions, the choice of thresholds, etc.), other than a pre-marked cell list, can be entered on the command line. The ease of application is an asset for flow physics research and preliminary design CFD analysis where fast grid modification is often needed to deal with unanticipated development of flow details. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This is a continuation under 37 CFR 1.53(b) to application Ser. No. 09/733,276, “External Counterpulsation Unit,” filed on Dec. 8, 2000 now U.S. Pat. No. 6,620,116 by Michael P. Lewis, The parent application is under examination in Group Art Unit 3764 by Examiner Danton DeMille.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not applicable.
FIELD OF THE INVENTION
The present invention is an improved medical cuff for non-invasive pulsation, including counterpulsation or simultaneous pulsation, treatment of patients utilizing at least one electromechanically controlled cuff wherein said cuff contains a fixed volume of a fluid such as air, water, or gel, and which constricts and expands upon electrical activation based on an integral actuator unit.
BACKGROUND OF THE INVENTION & RELATED ART
There are a variety of medical conditions in which the heart cannot pump sufficient blood to meet the body's normal requirements for nutrients and oxygen. Congestive heart failure is one condition in which the heart cannot pump enough blood to meet the needs of the body's other organs. Cardiac output can be too low for a variety of reasons, including coronary artery disease, endocarditis and myocarditis, diabetes, obesity, past heart attacks, high blood pressure, congenital defects, valve disease, or thyroid disease, to name a few. Where cardiac output falls, blood returning to the heart through veins can accumulate before the heart, causing fluid accumulation in the tissues. When cardiac output is too low, the body may take compensatory action including retention of salt by the kidneys. In response to salt retention, the body may retain greater quantities of water to balance sodium, and excess fluids can escape from the circulatory system causing edema (swelling) in other parts of the body. Edema is one of many complications arising from reduced cardiac output and congestive heart failure. The present invention is useful in treating edema, congestive heart failure and reduced cardiac output. Coronary artery disease is another condition that results in insufficient quantities of blood being pumped. Angina pectoris is a condition resulting from coronary artery disease. The present invention is useful in treating both coronary artery disease and angina pectoris.
There have been various devices in the prior art to treat patients through the use of non-invasive units and pulsation, but they are limited in their mechanical operation, precision of operation, stimulation of blood flow, and have failed to address concerns of the present invention.
External counterpulsation developed as a means of treating reduced cardiac output and circulatory disorder stemming from disease. Counterpulsation treatment involves the application of pressure, usually from distal to proximal portions of a patient's extremities, where such application is synchronized with heart rhythms. The treatment augments blood pressure, typically increasing pressure during the diastolic phase of the heart, as such treatment is known to relieve and treat medical conditions associated with reduced cardiac output. Clarence Dennis described an early hydraulic external counterpulsation device and method of its use in U.S. Pat. No. 3,303,841 (Feb. 14, 1967). Dr. Cohen, in American Cardiovascular Journal (30(10) 656–661, 1973) described another device for counterpulsation that made use of balloons which would sequentially inflate and deflate around the limbs of a patient to augment blood pressure. Similar devices using balloons have been described in Chinese patents CN 85200905 (U.S. Pat. No. 4,753,226); Chinese patents CN 88203328, and CN 1057189A.
A series of Zheng patents, including U.S. Pat. No. 4,753,226 (Jun. 28, 1988), U.S. Pat. No. 5,554,103 (Sep. 10, 1996), and U.S. Pat. No. 5,997,540 (Dec. 7, 1999) disclose counterpulsation devices employing sequential inflation of balloon cuffs around the extremities, wherein cuffs are inflated by fluid. All three Zheng patents disclose an external counterpulsation device where a series of air bladders are positioned within a rigid or semi-rigid cuff around the legs. The bladders are sequentially inflated and deflated with fluid, such that blood pressure is augmented in the patient. The Zheng '103 and Zheng '540 patents provide for cooled fluid and for monitoring of blood pressure and blood oxygen saturation; however, both retain a similar mechanism dependent on compression of fluid such as air or water. The Zheng '540 modifies the shape of the air bladder and cuffs, but retains a similar mechanism requiring rapid fluid distribution, influx and efflux through balloons in the cuffs.
Deficiencies with the prior counterpulsation cuffs include the requirement of a relatively heavy and noisy compressor and fluid reservoirs for inflating and deflating the cuffs; a lack of portability due to the size and weight of the apparatus; and the need for more than a 120 volt current. There are deficiencies with regard to patients being bounced up and down while subjected to the treatment. Additionally, because the prior art requires circuitous movement of fluid through the apparatus, there is a consequent lack of ability to manipulate action of the cuffs with a high degree of precision. Moreover, as the cuff returns only to an original position of contact with the patient's skin, blood-flow through the cuffed extremity is not fully encouraged.
BRIEF SUMMARY OF THE INVENTION
It is therefore the object of the present invention to provide a pulsation, including counterpulsation or simultaneous pulsation, cuff that compresses by electromechanical, rather than by pneumatic, means wherein said means is integral to the cuff, and which can be precisely controlled by the operator. It is a further object of the invention that the cuff may be constructed to create a vacuum about the extremity so as to encourage blood flow after constriction. It is a further object of the invention that the cuff may be expanded from its initial size so as to stimulate expansion of blood vessels by application of a vacuum against the extremity. It is a further object of the invention that the cuff transmits data regarding local pressure. It is a further object of the invention that after application the cuff be adjustable such that the cuff may apply fixed pressure, positive or negative, less than the maximum pressure, positive or negative, at times during operation.
The present invention provides a cuff with integral actuators and which may be constructed so as to encourage blood flow after constriction.
The present invention allows the operator to vary the constriction pressure and vacuum level applied by each cuff with a high degree of precision. This improvement is in contrast to prior art which uses the same pressure in multiple cuffs.
The present invention allows the operator to vary the duration and strength of compression, relaxation and expansion of each cuff.
The present invention provides a more comfortable cuff for patients as they are not repeatedly bounced up and down by inflation and deflation, and because the noise level of the apparatus is significantly reduced by use of electromechanical cuff actuators.
In the preferred embodiment, the present invention provides a more accessible treatment due to its portability, significantly reduced weight, and ability to run on a 120 volt current.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an isometric view of an unfastened electromechanical actuator cuff used in pulsation, including counterpulsation or simultaneous pulsation, treatment and designed for affixation to a patient's extremities.
FIG. 2 is an end view of the electromechanical actuator cuff depicted in FIG. 1 and additionally has a sectional view of cuff construction at the top of the page.
FIG. 3 is an end view of the electromechanical actuator cuff in FIGS. 1 and 2 as the cuff would appear fastened during use.
FIG. 4 is an isometric view of an electromechanical actuator cuff comprising an upper and lower section and which is an embodiment of the cuff for use on a patient's lower torso.
FIG. 5 is an end view of the electromechanical actuator cuff depicted in FIG. 4 and additionally provides sectional views.
FIG. 6 is an end view of the electromechanical actuator cuff in FIGS. 4 and 5 as the cuff would appear during use.
FIG. 7 depicts preferable orientations and constructions of flexible bladder sections used in the cuff of this invention.
DETAILED DESCRIPTION OF THE INVENTION
This invention is a cuff for use in external pulsation, including counterpulsation or simultaneous pulsation treatment of reduced cardiac output, congestive heart failure, angina pectoris, heart disease and other circulatory disorders. Counterpulsation has traditionally involved the application of sequential pressures on the lower legs, upper legs and buttocks through pneumatic cuffs placed on those regions. Application of pressure to the extremities has been timed to correlate with a patient's physiological rhythms, such as diastolic and systolic phases of the heart. This application of force by the cuff pushes blood upward toward the heart, whereby blood pressure is increased during the diastolic phase of the heart. This enhanced pressure is recognized as medically beneficial for treatment of medical conditions relating to blood circulation. The present invention, however, does not make use of pneumatic or inflatable devices for application of pressure. Rather, the present invention is an electromechanically controlled cuff that compress on activation and applies pressure to a patient's body wherein the actuator is integral to the cuff. Rather than pneumatic or inflatable devices, the present invention uses constriction means attached to the cuff; the cuff is typically filled with fluid, air, gel, or foam material. The cuff is primarily a flat structure designed to radially envelope an extremity such as a leg, arm, or midsection of a body. When the extremity is enveloped, the cuff is secured to itself in a manner such that electrical activation of actuators on the cuff will cause the cuff to constrict, thereby applying pressure to the extremity or portion of the body to which it is affixed, relax thereby applying no pressure, or expand, thereby creating a vacuum against the extremity of portion of the body to which it is affixed. Electromechanical means for constriction/expansion of the cuff is preferably one or more solenoid actuators (linear or rotary) connected at one end of the cuff and attached to a rod or rigid strap connected at the opposite end of the cuff. In an alternative embodiment, the electromechanical means on a first cuff section may be connected to the end of a mating cuff section thereby creating a full cuff. Positive pressure from the cuff forces blood from the extremity toward the patient's heart during diastole. It is this augmentation of blood pressure during diastole that provides curative benefit from counterpulsation treatment. Typically, the cuff will release immediately prior to the systolic phase of the patient's heart. In an alternative embodiment, a further improvement over the prior art is the use of the electromechanical means for expansion of the cuff to create a vacuum adjacent the skin to promote blood circulation between constrictions. A vacuum is created by creating a seal at each edge of the cuff with the adjacent skin and a seal at the overlapping sections of the cuff, then expanding the electromechanical means to a point beyond the original location.
Because the clinician may adjust the sequence in which the actuators are activated, blood can be forced away from the heart to a foot or hand. This is beneficial when treating a diabetic patient with poor blood circulation to these extremities.
FIG. 1 represents a single section electromechanical actuator cuff 23 used with the present invention and for use with pulsation, including counterpulsation or simultaneous pulsation, treatment. The cuff is actuated to apply pressure, positive or negative, according to treatment parameters and correlate with the patient's physiological data, such as diastolic and systolic phases of the heart, to augment blood pressure as necessary. The pressure strength, pressure duration, and delay between activations can be varied separately for each cuff and individual actuator used in treatment. The actuators on the cuff can apply pressure in many combinations of sequence, amount of pressure, and duration. Three preferable manners are: first, where pressure is graded, second where pressure is applied sequentially and third where graded pressure is applied sequentially. Pressure strength, pressure duration, and delay between actions can also be varied upon relaxation of the cuff and individual actuators. The actuators on the cuff relax in three preferable manners: first where pressure is graded, second where pressure is relaxed sequentially and third where graded pressure is relaxed sequentially. Pressure on a patient can also be released by all actuators simultaneously or in any sequence.
Graded pressure means that each cuff, or each actuator on each cuff, is set to apply a specific and not necessarily identical amount of pressure. For example, the cuff or actuators at a patient's calves may be set to apply pressure at a greater strength than the cuff or actuators affixed to a patient's thighs. In this manner, even where all actuators apply pressure simultaneously, pressure will vary at separate locations on the patient. Actuators are preferably adjusted so that pressure will increase or decrease from distal to proximal direction on a patient or vice versa. Each actuator and each cuff may also release pressure at variable sequences and at varying strengths. Pressure on a patient can be applied one actuator at a time, in any sequence, and at any pressure within treatment parameters.
An actuator cuff and individual actuators can apply sequential pressure to a patient. A cuff and actuators preferably apply pressure, positive or negative in sequence, from a distal to proximal direction or vice versa. An individual cuff or actuator may be removed from a sequence of activations, or can be set independently so that one cuff or one actuator in a series applies pressure, positive or negative, more frequently per period of time than will a separate cuff or individual actuator. Each cuff and individual actuators will preferably operate in sequence, whether or not there are gradations in pressure from actuator to actuator or from cuff to cuff.
Graded sequential pressure involves variations in constriction/vacuum force (pressure) from actuator to actuator or from cuff to cuff and where actuators or the cuff will operate in sequence. For example, actuators at a patient's calves may be set to apply greater pressure, positive or negative than actuators fixed to the cuff on a patient's hips. In addition to graded pressure, the actuators are set to activate in sequence starting from the patient's calves and moving upward to the actuator on the patient's hip. In this same example, actuators would relax in like sequence, thereby creating a precisely controlled peristaltic motion by the cuff on the patient.
The cuff applies pressure preferably in sequence on a patient from a distal to proximal direction generally with increments in the range of 35.0 to 50.0 milliseconds between initial activation of separate sequential cuffs. Each cuff preferably relaxes or applies negative pressure in sequence on a patient from a proximal to distal direction. All actuators on each of cuff preferably operate within a compression strength range of −1.0 and +7.0 pounds of pressure per square inch for each actuator. The cuff is also able to compress, relax, or expand in the opposite direction, from proximal to distal direction on the patient and in the same time increments.
FIG. 1 depicts an electromechanical actuator cuff designed for affixation to a patient's extremities (arms, legs). The preferable rectangular shape of the cuff can be varied by manufacture or adjustment to accommodate different body shapes and sizes. For instance, the actuator cuff depicted in FIG. 1 may be adapted in size to fit a calf, thigh, forearm, upper arm, or wrist of an infant, child, or adult patient. Additionally, each cuff in the present pulsation, including counterpulsation or simultaneous pulsation, unit is preferably adapted in a more conical or trapezoidal shape to accommodate increasing or decreasing thicknesses of patient extremities. Trapezoidal shaping improves the cuff's ability to encompass a patient's extremity and receive optimal benefit of actuator constriction and expansion.
FIG. 6A depicts an exploded view of the embodiment of FIG. 6 .
FIG. 7 depicts a double section embodiment of the actuator cuff 24 . The double section embodiment 24 is affixed to the patient's buttocks and hips. While more than one cuff can be operated simultaneously, each cuff and each of the actuators on each cuff can be operated separately with different or identical compression/expansion sequences, strengths, and delays between each individual actuator cuff or between individual actuator activation or relaxation. For instance, with the present invention, it would be possible to cause an actuator on a particular cuff to constrict more frequently in a set period of time than the other actuators on the same cuff. Additionally, the cuff of the present invention is able to apply pressure, positive or negative, to an extremity almost instantaneously from the time the activation signal is sent due to its electromechanical rather than pneumatic operation. Pressure can additionally be altered with a high degree of precision with the present invention. Counterpulsation typically relies on reduction of pressure on the patient's extremities during the systolic phase of the heart. Instead of instant deflation of all cuffs at systole, the present invention, which does not require deflation, can vary the time frames during systole and the degree of pressure on each cuff. The present invention, which does not rely on inflation or deflation, can more aptly gradually reduce pressure with each cuff and each individual cuff actuator.
In FIG. 1 the dimensions of one embodiment of the electromechanical actuator cuff are depicted. The width 14 of the cuff depicted in FIG. 1 is in the range of 1.0 and 20.0 inches; the length 13 is in the range of 4.0 and 40.0 inches. The actuator cuff thickness 19 as shown in FIGS. 2A and 2B , means the sum measurement of a typical cuff construction, including flexible surface layer 1 , flexible bladder section 7 , and flexible liner layer 6 at its thickest point in the cuff in the range of 0.1 and 3.0 inches. The actuator cuff can be made of one material throughout its thickness, but typically has more than one layer, including a flexible surface layer 1 that is made of a material for flexibility, appearance, durability, and strength. This flexible surface layer 1 is typically of Kevlar, plastic, nylon, or aramid. The flexible surface layer 1 , is preferably made from a resilient construction which will not have significant stretch within the range and duration of the unit's operation. Flexible layer 1 may be made of a material that has sufficient resistance to deflection so as to provide all energy needed to create negative pressure between the cuff and skin upon cessation of positive pressure by the actuator unit. In an alternative embodiment the rod or rigid strap would be eliminated by such material used to create negative pressure against the skin before operation.
As depicted in all figures, contiguous with the bottom of flexible surface layer 1 is typically a flexible bladder section 7 , which contains a fixed volume of fluid substance. Flexible bladder section 7 preferably contains a fluid such as air, gel, foam substance, beads (typically plastic), or water. Bladder section 7 is flexible to bend with the actuator cuff on compression or expansion. The bladder section 7 may be filled with fluid prior to use of the cuff, however, it does not inflate or deflate upon activation of the cuff. Bladder section 7 is preferably comprised of a plurality of bladder subsections 25 (shown in FIG. 2B ), which run along the width of a cuff, and with empty cavities 26 between each subsection 25 . These bladder subsections 25 and empty cavities 26 further enhance flexibility of the bladder section 7 and cuff as it constricts or expands during operation. A pressure sensor and/or a pressure relief valve (not shown) may be constructed at the point at which the bladder in inflated and deflated. Inflation of the bladder permits the cuff to better conform to the contour of the area upon which it is placed and to provide a heat-absorbent enclosure. A pressure sensor may provide data to an external control unit for adjustment of the positive or negative pressure applied to the patient. A pressure relief value prevents damaging overcompression of the patient by the cuff.
FIG. 3 is an end view of the electromechanical actuator cuff depicted in FIG. 1 . It provides a more detailed picture and sectional view of the flexible surface layer 1 as it is preferably positioned in one embodiment relative to the flexible bladder section 7 , flexible liner layer 6 , and pressure sensor 8 . Additionally, FIG. 3 provides a detailed view of bladder subsections 25 and empty cavities 26 that preferably comprise the flexible bladder section 7 .
FIG. 7 depicts an embodiment of the flexible bladder section 7 , wherein bladder sections run along the length of a cuff and are situated contiguous with the bottom of the flexible surface layer 1 in such manner that each actuator unit 3 and extension attachment 4 is complimented by a separate portion of flexible bladder section 7 . This embodiment is preferable as separate actuators can compress differently on the same cuff, while retaining the support afforded by a separate bladder section. This flexible bladder section 7 arrangement therefore provides support for the portion of the cuff that is compressed on individual actuator activation. FIG. 7 demonstrates with broken lines the location of two separate flexible bladders 7 as they are situated in the same cuff, each bladder contiguous with the bottom of the flexible surface layer 1 , and situated beneath an actuator unit 3 and respective extension attachment 4 . The top of FIG. 7 shows cross sectional views of two typical flexible bladder section 7 constructions. The cross sectional view 27 on the left side of FIG. 7 is identical to prior descriptions of the flexible bladder section 7 depicted in FIG. 2 , except for the difference in orientation of the bladders, namely that separate bladder sections 7 are situated beneath each actuator unit 3 and respective extension attachment 4 on the same cuff. The second cross sectional view 28 depicts a construction wherein the flexible bladder section 7 is continuous throughout (without any subsections across the bladder width) and adapted to receive a fixed volume of fluid, such as water, air, gel, or foam substance. Cross sectional view 28 depicts a continuous construction throughout, meaning without bladder subsections 25 or empty cavities 26 running width-wise, however, a construction as depicted in cross section 28 may still be divided so that on the same cuff flexible bladder section 7 is comprised of separate sections situated beneath each actuator unit 3 and respective extension attachment 4 .
Contiguous with the bottom of flexible bladder section 7 is preferably a flexible liner layer 6 , that accomplishes friction reduction and sealing of opposite ends of the cuff during activation of the cuff. The liner layer 6 is typically of a construction material having a low coefficient for friction such as Teflon, plastic, nylon, or aramid. Additionally, one or more pressure sensors 8 are typically imbedded or attached to the actuator cuff. Pressure sensors 8 may be imbedded in flexible surface layer 1 , flexible liner layer 6 , or flexible bladder section 7 . Preferably, pressure sensors are connected to the flexible bladder section 7 to monitor air pressure in the bladder. Such sensors are able to detect material strain in the cuff or air pressure in the bladder or pressure, negative and/or positive between the cuff and skin and electronically transmit this information for processing by computer means. The pressure sensors 8 thereby provide electronic feedback data and detect the degree of compression accomplished by the actuator cuff and individual actuators during operation. This data can be interpreted during treatment for adjustment of cuff and actuator activation.
Compression or expansion of the cuff may be correlated with physiological data including, but not limited to EKG, plethysmograph, cardiac output, heart rate, blood pressure, heart stroke volume, blood oxygen levels, systole and diastole. A variety of devices in the medical industry are used to detect and electrically transmit this physiological data from a patient. After such data is collected, it is typically processed within pulsation parameters to determine proper sequence of cuff activation. Such data is received by and processed, typically with a computer and software designed for pulsation. Typically, a computer processes the patient's electronic physiological data as well as electronic feedback data derived from pressure sensors 8 built into the cuffs and can change treatment parameters based on either input from the clinician or from a processor program. These pressure sensors 8 detect and transmit data on the amount of pressure, positive or negative, being applied by the cuff during operation.
When a cuff is applied to a patient, it is typically wrapped around the patient's extremity or lower torso and its ends are fastened together and held tautly with extensions 5 . When negative pressure is desired extensions 5 are preferably adjustable rods or rigid strap unless the cuff itself will spring open sufficiently far and sufficiently quickly to provide the desire vacuum effect. When negative pressure is not necessary extension 5 may be a flexible strap, typically a synthetic material such as high strength nylon, having both a layer of tiny hooks and a complementary layer of a clinging pile; so that the two layers of material can be pulled apart or pressed together for easy fastening and unfastening, and for attachment of both ends of the actuator cuff.
The cuff of the present invention operates by electromechanical means to apply pressure, negative or positive. This application of pressure is typically accomplished through use of actuators 3 A housed on top of the flexible surface layer 1 . Actuators 3 A are preferably solenoid devices of either linear or rotary operation. FIG. 1 depicts where actuators units 3 are typically positioned on the present invention. Actuator units 3 are comprised of an actuator 3 A, actuator attachment 3 B, and the actuator housing 3 C. Typically affixed on the top of the flexible surface layer 1 are the actuator units 3 , and extensions attachments 4 . The present invention preferably has one or more extension attachments 4 more toward one end of the flexible surface layer 1 to which extensions 5 are connected. FIGS. 1 , 2 , and 3 further depict an opposite end of the flexible surface layer 1 on top of which are one or more actuator units 3 . Each of these actuator units 3 is situated across and opposite from extension attachment 4 . This arrangement permits for adjustment of extension 5 between the actuator attachment 3 B and the extension attachment 4 when the cuff is wrapped around a patient. The actuator attachment 3 B is affixed to the actuator 3 A that is in turn positioned within the actuator housing 3 C. On electromechanical activation to apply positive pressure, the actuators 3 A move away from the cuff end (toward the cuffs center), and within the actuator housing 3 C which remains stationary. The extensions 5 are attached on one end to the actuator attachment 3 B that is attached to the actuator 3 A, and on opposite end of the extension 5 to the extensions attachments 4 . Consequently, compression movement of the actuators 3 A draws extension 5 towards actuators 3 A, thereby causing the cuff to constrict. Preferably, the extensions attachments 4 and actuator units 3 have force distribution footings 2 to better resist strain during cuff activation. The force distribution footings 2 are preferably stair-stepped, and pyramidal, in shape.
FIG. 1 further depicts a cuff where the flexible surface layer 1 is shaped to afford contour of fit during activation. Contouring allows the ends of a cuff to fit together smoothly when the cuff is affixed to a patient. Also, contouring of the layers serves to make a more comfortable device for patients because contoured cuff ends will not pinch a patient during operation of the cuff. FIGS. 1 and 2 both show contouring typical of an unfastened flexible surface-layer 1 . For example, the flexible surface layer 1 is stepped down from top to bottom along the entire width of the cuff and at a stepped point 12 just beyond the extension attachments 4 . This step decreases the thickness of the flexible surface layer 1 along its entire width making an overlap section 10 . At a point closer to the end of the flexible surface layer 1 , the thickness is preferably tapered to a point, the tapered end 9 . The entire width of the opposite end of the flexible surface layer 1 preferably forms an abrupt taper 11 upward from a point beginning from the bottom of the flexible surface, layer 1 and at a point beyond contact with the flexible bladder section 7 .
In an alternative embodiment, a seal at each edge 29 of cuff 23 and the patient (not shown) is created and a seal is created between edge 30 of cuff 23 and edge 31 of cuff 23 . As a result of the three seals, a fixed volume of air is created between patient (not shown) and cuff 23 . Tensile movement of the actuators 3 A forces extension 5 away from actuator 3 A, thereby causing the cuff to expand. As the fixed volume of air does not significantly vary, a vacuum is created, reducing the pressure of the fixed volume of air and thereby causing expansion of the patient's limb or member. Such expansion encourages blood flow into the formerly constricted blood vessels which may permit a greater volume of blood to be forced towards the heart during the next constriction sequence and may permit more rapid application of the next constriction sequence.
FIG. 3 is an end view of the electromechanical actuator cuff embodied in FIGS. 1 and 2 as the cuff would appear during use. Opposite ends of the cuff are rolled toward one another in circular fashion for affixation around a patient's body and/or extremities. The entire electromagnetic cuff is flexible, but when placed around a human extremity, would appear primarily circular as pictured. Fit contouring of the flexible surface layer 1 is also shown, including the stepped point 12 which defines a beginning of the flexible overlap section 10 , and which further narrows to a tapered end 9 . This overlap section 10 wraps around in circular fashion to meet the opposite end of the flexible surface layer 1 that preferably culminates in an abrupt taper 11 . The diameter 20 of this fastened cuff will vary in the range of 1.0 and 20.0 inches, variable on activation. FIG. 3 further depicts an extension 5 as it would appear in fixed position between an extension attachment 4 and the actuator attachment 3 B.
FIG. 4 defines a separate embodiment of the electromechanical actuator cuff. This double section cuff 24 embodiment, shown in FIGS. 4 , 5 , 6 and 6 A is designed for affixation to wider parts of a human body such as the torso, thorax, and buttocks. It is, however, possible that such device could be used on the extremities such as arm and legs as part of pulsation, including counterpulsation or simultaneous pulsation, treatment. As with the single section cuff 23 shown in FIGS. 1 , 2 , and 3 , the double section cuff 24 compresses on electromechanical activation, and is designed to correlate with physiological data obtained from a patient, however, this embodiment 24 is comprised of two separate sections. Unlike the first single section cuff 23 that has both actuator units 3 and tension strap attachments 4 affixed to the same flexible surface layer 1 , this second embodiment 24 has a plurality actuator units 3 fixed on one upper section 21 , and tension strap attachments 4 fixed on a separate lower section 22 . The two sections of the cuff fit together and constrict as depicted in FIGS. 6 and 6A . On activation, both upper and lower sections of the cuff move toward one another, constricting, and applying pressure to the portion of the patient's body to which the cuff was affixed.
The two section cuff 24 depicted in FIG. 4 is made up of an upper section 21 and a lower section 22 that are adapted to connect to one another. Both upper section 21 and lower section 22 have a flexible surface layer 1 similar to that in the single section cuff 23 , however with different contouring. On both the upper 21 and lower 22 section of the actuator cuff, thickness 19 , meaning the sum measurement of either one layer or of a preferable cuff construction comprising a flexible surface layer 1 , flexible bladder section 7 , and flexible liner layer 6 , is its at thickest point between 0.1 and 3.0 inches. As with the single section cuff 23 , the upper section 21 and lower 22 sections of the actuator cuff have a preferable flexible surface layer 1 that is made of a material for flexibility, appearance, durability, and strength. The flexible surface layer 1 is typically made from Kevlar, plastic, nylon, aramid, Mylar, a Teflon®-coated material or smooth plastic. The flexible surface layer 1 , is preferably made from a resilient construction that will not have significant stretch within the range and duration of the unit's operation. In both the upper 21 and lower 22 sections, contiguous with the bottom of the flexible surface layer 1 is preferably a flexible bladder section 7 that contains a fixed volume of fluid or gel material. The bladder section typically contains fluid such as air, gel, foam substance, or water. The bladder section 7 is flexible so that it bends with the actuator cuff, but does not inflate or deflate pneumatically upon activation of the cuff. As with the single section cuff 23 , the bladder section 7 is typically comprised of bladder subsections 25 , with empty cavities 26 between each subsection so as to enhance flexibility of the bladder section 7 and cuff as a whole during operation.
In yet another embodiment of the flexible bladder section 7 , bladder sections run along the length of each cuff and are situated contiguous with the bottom of the flexible surface layer 1 in such a manner that a pair of actuator units 3 of the upper section 21 and respective pair of extensions attachments 4 of the lower section 22 are supported by a portion of flexible bladder section 7 running longitudinally on one side of each cuff section. Flexible bladder sections on each side of separate lower 22 and upper 21 sections work together providing support independent of support provided by the flexible bladder section 7 portion situated on an opposite side of the same cuff for separate respective actuator units 3 and extension attachments 4 .
FIG. 7 shows cross sectional views of two typical flexible bladder section 7 constructions on the single section cuff embodiment 23 that are useful for showing the same embodiment on the double section cuff embodiment 24 . The cross sectional view 27 on the left side of FIG. 7 is identical to prior descriptions of the flexible bladder section 7 depicted in FIG. 2 , except for the difference in orientation of the bladders. The flexible bladder section 7 is divided into two sections that run longitudinally along the side of each cuff so as to support a pair of actuator units 3 (if on the upper section 21 ) or a pair of extension attachments 4 (if on the lower section 22 ). The second cross sectional view 28 depicts a construction wherein the flexible bladder section 7 is continuous throughout (without any subsections across the bladder width) and adapted to receive a fixed volume of fluid, such as water, air, gel, beads (typically plastic), or foam substance. Cross sectional view 28 depicts a continuous construction throughout, meaning without bladder subsections 25 or empty cavities 26 running width-wise, however, a construction as depicted in cross section 28 may still be divided so that each cuff section (both upper and lower) preferably have a flexible bladder section 7 comprised of separate sections situated beneath each actuator unit 3 and respective extension attachment 4 .
As with the single section cuff 23 , and in both upper 21 and lower 22 sections of the cuff, contiguous with the bottom of the flexible bladder section 7 is preferably a flexible liner layer 6 that accomplishes friction reduction and sealing ends of the cuff during activation of the cuff. This liner layer 6 is typically made of Kevlar, Mylar, a Teflon®-coated material or smooth plastic. The liner layer 6 is typically of a construction material having a low coefficient for friction. Preferably, in both upper section 21 and lower section 22 of the actuator, one or more pressure sensors 8 are imbedded in the actuator cuff. Sensors 8 are able to detect material strain in the cuff or pressure, negative and/or positive between the cuff and skin or in bladder section 7 and transmit this information for processing. The pressure sensors 8 thereby detect the amount of pressure applied accomplished by the actuator cuff during operation. Pressure sensors 8 are imbedded in flexible surface layer 1 , flexible liner layer 6 , or attached to the flexible bladder section 7 . Preferably, pressure sensors 8 are connected to the bladder section 7 next to the liner layer 6 . The electromechanical mechanism in the double section cuff embodiment 24 is essentially the same as that with the single section cuff embodiment 23 , however, with a difference being that actuator units 3 and extension attachments 4 are not affixed to the same surface on the second cuff embodiment 24 .
In this two section cuff embodiment 24 , on the top of the flexible surface layer 1 of the upper section 21 are a plurality of actuator units 3 , and contained actuator attachments 3 B. All of the extension attachments 4 , however, are on the lower section 22 of the cuff and attached to the flexible surface layer 1 on the side opposite the flexible bladder section 7 . As depicted in FIGS. 4 and 5 , the lower section 22 has a plurality of extension attachments 4 from which are attached a plurality of extensions. Extensions are adapted at one end to be received by the actuator units 3 , and contained actuator attachments 3 B on the upper section 21 of the actuator cuff. Opposite ends of the extensions are adapted to be received by extension attachments 4 fixed on the cuffs lower section 22 . Actuator units 3 and extension attachments 4 have force distribution footings 2 . On operation of the two section cuff 24 , the actuators 3 A move to or away from the center of the upper section 21 and pull extensions which are connected to extension attachments 4 on the lower section 22 of the two section cuff 24 . As a result, the upper section 21 and lower section 22 constrict or expand, applying pressure, positive or negative, to a patient at the point where the cuff is affixed on the patient's body.
Both the lower section 22 and upper sections 21 of the cuff have similar construction, usually a flexible surface layer 1 , flexible bladder section 7 , pressure sensor 8 , and flexible liner layer 6 . The upper section 21 and lower section 22 are different in terms of their geometric dimensions (length and width) and with regard to fit contours of their respective flexible surface layers 1 . FIG. 4 shows the lower section 22 of the cuff is typically defined on opposite ends of its length by a stepped point 12 from which point the thickness of its flexible surface layer 1 is decreased (as in the first cuff embodiment); forming an overlap section 10 ; and where the overlap section 10 continues and preferably culminates with a tapered end 9 . Opposite ends of the lower section 22 mirror one another from a hypothetical midline across the lower section's width. The lower section width 16 is in the range of 2.0 and 20.0 inches and the longest lower section length 15 is in the range of 10.0 and 40.0 inches. The upper section 21 in FIG. 4 is different from the lower section 22 in terms of dimension and fit contouring of the flexible surface layer 1 . The upper section width 17 is in the range of 2.0 and 20.0 inches and the upper section length 18 is in the range of 5.0 and 30.0 inches. The upper section 21 has preferably an abrupt taper 11 that extends along the entire width of opposite ends. Such abrupt tapers 11 begin typically on the flexible surface layer 1 at each end at a point beyond contact with the flexible bladder section 7 . The abrupt taper 11 depicted in FIGS. 4 and 5 on the upper section 21 is identical to the abrupt taper depicted in Figure 1 .
FIG. 5 is an end view of the electromechanical actuator cuff depicted in FIG. 4 and additionally provides sectional views.
FIG. 6 provides an end view of the electromechanical actuator cuff in FIGS. 4 and 5 as the cuff would appear during use when the upper 21 and lower 22 sections are fit together around a patient. The extensions are shown as they appear when fixed between the actuator attachment 3 B and extension attachment 4 . FIG. 6 additionally depicts how contouring of the flexible surface layers 1 of both upper 21 and lower 22 sections accomplishes a smooth fit between parts. The flexible surface layer 1 of the lower section 22 forms an overlap section 10 from a stepped point 12 and culminates with a tapered end 9 . On electrical activation, the actuators 3 A and actuator attachments 3 B move away from the upper section 21 ends and toward the center or in the opposite direction. When the actuators 3 A and actuator attachments 3 B move away from the upper section 21 ends and toward the center the extensions tighten and the upper 21 and lower 22 sections of the cuff constrict. In reverse, the cuff applies pressure. A pressure sensor 8 as shown in FIG. 6 detects the amount of material strain in the cuff or pressure, negative and/or positive between the cuff and skin in the cuff or pressure in the bladder and electronically transmits data regarding the cuffs action. Both upper 21 and lower 22 sections contain pressure sensors 8 .
The foregoing disclosure and description of the invention is illustrative and explanatory thereof. Various changes in the details of the illustrated construction may be made within the scope of the appended claims without departing from the spirit of the invention. The present invention should only be limited by the following claims and their legal equivalents. | This invention is an improved medical device for non-invasive pulsation, including counterpulsation or simultaneous pulsation, treatment of heart disease and circulatory disorder through external cardiac assistance. The device is a cuff which is affixed on a patient's lower body and extremities, and which constricts or expands by electromechanical activation, thereby augmenting blood pressure for treatment purposes. The cuff contains preferably fixed volume fluids such as gel, air, or water. The cuff envelops and is affixed to the patient's lower body and limbs. In an alternative embodiment, the cuff creates a fixed volume of air between the cuff and the patient such that the cuff creates a vacuum when expanding, thereby stimulating return of blood to the constricted region, permitting better and/or faster responses. | 8 |
This application claims the benefit of U.S. Privisional Application Ser. No. 60/092613, filed Jul. 13, 1998.
BACKGROUND OF THE INVENTION
The invention described herein relates to a process for synthesizing 1β-methyl-2-hydroxymethyl carbapenem intermediate compounds that are useful in the synthesis of carbapenems. Generally the carbapenems are substituted at the 2-position. The intermediate compounds are included as well.
European applications 0330108, 0102239, 0212404, 0695753 and 0476649 disclose methods for synthesizing various antibiotic derivatives. Likewise, U.S. Pat. No. 4,350,631 issued to Christensen, et al. on Sep. 21, 1982 and in U.S. Pat. No. 4,994,568 issued to Christensen on Feb. 19, 1991 also discloses various antibiotic derivatives and methods of making.
Many of the carbapenems are useful against gram positive microorganisms, especially methicillin resistant Staphylococcus aureus (MRSA), methicillin resistant Staphylococcus epidermidis (MRSE), and methicillin resistant coagulase negative Staphylococci (MRCNS). These antibacterials thus comprise an important contribution to therapy for treating infections caused by these difficult to control pathogens. There is an increasing need for agents effective against such pathogens (MRSA/MRCNS) which are at the same time relatively free from undesirable side effects.
SUMMARY OF THE INVENTION
The invention describes an improved process for synthesizing 1β-methyl-2-hydroxymethyl substituted carbapenems as key intermediates for the synthesis of anti-MRSA carbapenem antibiotics. Previously, intermediates of 1p-methyl-2-hydroxymethyl substituted carbapenems were prepared by a Stille-type cross-coupling reaction using BuSnCH 2 OH and HMPA (see U.S. Ser. No. 60/056967, filed Aug. 26, 1997, Merck case number 19988PV). This new synthesis eliminates the use of Bu 3 SnCH 2 OH and HMPA. The novel intermediates are also within the scope of this invention.
DETAILED DESCRIPTION OF THE INVENTION
The present invention relates to a process for making 1β-methyl-2-hydroxymethyl substituted carbapenems which are key intermediates in the synthesis of anti-MRSA carbapenem antibiotics (such as those disclosed in U.S. Pat. No. 5,756,725, issued May 26, 1998, the teachings of which are hereby incorporated by reference). The intermediates can be readily coupled to a wide range of functional groups (see U.S. Pat. No. 5,756,725).
In one aspect of the invention, a process of synthesizing a compound of formula 3:
is disclosed wherein
R 1 represents H or a suitable protecting group for an alcohol; R 2 represents H or methyl; and R 5 represents a carboxy protecting group
comprising adding a compound of formula 2:
wherein
R 1 , R 2 and R 5 are described above and R and R′ independently represent H, alkyl, O-alkyl, S-alkyl, N-alkyl, O-aryl, S-aryl, N-aryl, or aryl; said alkyl or aryl optionally substituted with 1-3 groups of N, S, O, and halo;
to a solvent in the presence of a catalyst to produce a compound 3.
The invention is described herein in detail using the terms defined below unless otherwise specified.
The term “alkyl” refers to a monovalent alkane (hydrocarbon) derived radical containing from 1 to 10 carbon atoms unless otherwise defined. It may be straight, branched or cyclic. Preferred alkyl groups include methyl, ethyl, propyl, isopropyl, butyl, t-butyl, cyclopentyl and cyclohexyl. When substituted, alkyl groups may be substituted with up to four substituent groups at any available point of attachment. When the alkyl group is said to be substituted with an alkyl group, this is used interchangeably with “branched alkyl group”.
Cycloalkyl is a specie of alkyl containing from 3 to 15 carbon atoms, without alternating or resonating double bonds between carbon atoms. It may contain from 1 to 4 rings which are fused.
The term “O-alkyl” refers to an oxygen atom attached to an alkyl such as an alkoxy.
The term “N-alkyl” refers to a nitrogen atom attached to an alkyl.
The term “S-alkyl” refers to an sulfur atom attached to an alkyl.
Aryl refers to aromatic rings e.g., phenyl, substituted phenyl and the like as well as rings which are fused, e.g., naphthyl, phenanthrenyl and the like. An aryl group thus contains at least one ring having at least 5 atoms, with up to five such rings being present, containing up to 22 atoms therein, with alternating (resonating) double bonds between adjacent carbon atoms or suitable heteroatoms. The preferred aryl groups are phenyl, naphthyl and phenanthrenyl. Aryl groups may likewise be substituted as defined. Preferred substituted aryls include phenyl and naphthyl.
Aryl also refer to heteroaryl, which is a monocyclic aromatic hydrocarbon group having 5 or 6 ring atoms, or a polycyclic aromatic group having 8 to 16 atoms, containing at least one heteroatom, O, S, S(O), SO 2 or N, in which a carbon or nitrogen atom is the point of attachment, and in which one or two additional carbon atoms is optionally replaced by a heteroatom selected from O or S, and in which from 1 to 3 additional carbon atoms are optionally replaced by nitrogen heteroatoms, said heteroaryl group being optionally substituted as described herein. Examples of this type are pyrrole, pyridine, oxazole, thiazole and oxazine. Additional nitrogen atoms may be present together with the first nitrogen and oxygen or sulfur, giving, e.g., thiadiazole and the like.
The term “S-aryl” refers to an sulfur atom attached to an aryl.
The term “N-aryl” refers to an nitrogen atom attached to an aryl.
The term “Oaryl” refers to an oxygen atom attached to an aryl.
Examples of polycyclic heteroaromatics include benzopyrans, benzofurans, benzopyrroles, benzimidazoles, benzothiazoles, quinolines, purines, isoquinolines, benzopyrimidines, dibenzofurans, dibenzothiophenes, 1,8-naphthosultams,
The term “heterocycle” (heterocyclyl) refers to a 5-16 membered cycloalkyl group (nonaromatic) with 1-4 rings, in which one of the carbon atoms in the ring is replaced by a heteroatom selected from O, S or N, and in which up to three additional carbon atoms may be replaced by heteroatoms.
The term “heteroatom” means O, S, S(O), S(O) 2 or N, selected on an independent basis.
Halogen and “halo” refer to bromine, chlorine, fluorine and iodine.
When a group is termed “protected”, such as R 1 , R 5 and the like, this means that the group is in modified form to preclude undesired side reactions at the protected site. Suitable protecting groups for the compounds of the present invention will be recognized from the present application taking into account the level of skill in the art, and with reference to standard textbooks, such as Greene, T. W. et al. Protective Groups in Organic Synthesis Wiley, N.Y. (1991). Examples of suitable protecting groups are contained throughout the specification.
In some of the compounds of the present invention, R 1 and R 5 represent alcohol and carboxyl protecting groups, respectively. These groups are generally removable, i.e., they can be removed, if desired, by procedures which will not cause cleavage or other disruption of the remaining portions of the molecule. Such procedures include chemical and enzymatic hydrolysis, treatment with chemical reducing or oxidizing agents under mild conditions, treatment with a transition metal catalyst and a nucleophile and catalytic hydrogenation.
Examples of carboxyl protecting groups R 5 include allyl, benzhydryl, 2-naphthylmethyl, benzyl, silyl groups such as t-butyldimethylsilyl (TBDMS), trimethylsilyl, (TMS), triethylsilyl (TES), phenacyl, p-methoxybenzyl, o-nitrobenzyl, p-methoxyphenyl, p-nitrobenzyl (pNB), 4-pyridylmethyl and t-butyl, preferably pNB.
Examples of suitable alcohol protecting groups R 1 include trialkylsilyl, diarylalkylsilyl, aryldialkylsilyl or trityl such as TMS, TES, TBDMS, carbonates and alkyl carbonates such as benzyl carbonate, benzyl ether, diarylalkylsilyl, aryldialkylsilyl and the like. Preferred R 1 groups are TMS, TES, TBDMS.
In still another aspect of the process the synthesis of a compound of formula 4:
is disclosed wherein
R 1 represents H or a suitable protecting group for an alcohol; R 2 represents H or methyl; and R 5 represents a carboxy protecting group
comprising adding a compound of formula 2:
wherein
R 1 , R 2 and R 5 are described above and R and R′ independently represent H, alkyl, O-alkyl, S-alkyl, N-alkyl, O-aryl, S-aryl, N-aryl, or aryl; said alkyl or aryl optionally substituted with 1-3 groups of N, S, O, and halo;
to a solvent in the presence of a catalyst to produce a compound 3:
wherein
R 1 , R 2 and R 5 are described above;
reducing a compound of formula 3 with a reducing agent to produce a compound of formula 4.
Suitable catalyst include RuCl 3 , RuO 2 , K 2 OsO 4 .2H 2 O, KMnO 4 , OsO 4 and the like or a combination thereof. The catalyst employed is generally from about 0.3 mol % to about 25 mol % of compound 2.
Suitable solvents for the invention disclosed herein include tetrahydrofuran (THF), ethyl acetate (EtOAc), H 2 O, C 1-6 alcohol, dichloromethane, acetonitrile, acetone and the like or a combination thereof, preferably THF or THF- H 2 O.
Suitable reducing agents are Cp 2 TiCl 2 /NaBH 4 , ZnCl 2 /NaBH 4 , BH 3 .SMe 2 , BH 3 .THF and the like.
In another aspect of the invention the process optionally contains from about 0.1 to about 15, preferably about 0.5 to about 6 equivalents, of an oxidizing agent representing NaIO 4 , HIO 4 , N-methylmorpholine N-oxide (NMO)-NaIO 4 , NaIO 4 -HIO 4, and the like, or a combination thereof.
The reaction is conducted at a temperature of about 0° C. to about 80° C., preferably about 15° C. to about 45° C. and most preferably about 20° C. to about 35° C.
In particular, processes of interest are those described above wherein R and R′ are hydrogen or R is H and R′ is CH 2 OH.
In the case where R 1 is TBS, it is preferable that the catalyst is OSO 4 , RuCl 3 and the like or a combination thereof. When an oxidant is employed it is preferable that it is NaIO 4 , HIO 4 or NaIO 4 -HIO 4 . The preferable temperature range is from about 20° C. to about 30° C., most preferably about room temperature.
In the case where R 1 is TES, it is preferable that the catalyst is OSO 4 , or K 2 OsO 4 .2H 2 O. When an oxidant is employed it is preferable that it is NaIO 4 , HIO 4 , NMO-NaIO 4 . The preferable temperature range is from about 20° C. to about 30° C., most preferably about room temperature. It is further preferred that the pH of the reaction be maintained at about 4 to about 8, more preferably at about 5 to about 7.
In still another aspect of the invention where R 1 is TES the process optionally contains a base representing pyridine, triethylamine, triethylamine, trimethylamine, ethyldimethylamine, tri-n-propylamine, 1,8-diazabicyclo[5.4.0]undec-7-ene (DBU), pyridine, imidazole, lutidine, collidine, 4-dimethylaminomethylpyridine, N,N,N′,N′-tetramethylethylenediamine (TMEDA), N-methylmorpholine (NMM) and the like.
In yet another aspect of the invention a process for making a compound of formula 3:
is disclosed wherein
R 1 represents H or a suitable protecting group for an alcohol; R 2 represents H or methyl; and R 5 represents a carboxy protecting group
comprising reacting a compound of formula 2:
wherein
R 1 , R 2 and R 5 are described above and R and R′ independently represent H, alkyl, O-alkyl, S-alkyl, N-alkyl, O-aryl, S-aryl, N-aryl, or aryl; said alkyl or aryl optionally substituted with 1-3 groups of N, S, O, and halo; with a first oxidant in the presence of a catalyst and acid (or buffer to control pH) to yield a compound of formula 5:
wherein
R, R′, R 1 , R 2 and R 5 are described above; and reacting a compound of formula 5 with a second oxidant to produce the compound of formula 3.
A suitable first oxidant represents a mild oxidant such as N-methylmorpholine N-oxide (NMO), or NMM-NaIO 4 (about 1 to about 4 equivalents of the catalyst).
A suitable second oxidant represents a strong oxidant such as NaIO 4 or HIO 4 .
A suitable acid represents acetic acid, 4-morpholinepropanesulfonic acid (MOPS), morpholineethanesulfonic acid (MES) and the like, from about 1 to about 6 equivalents.
In still another aspect of the process the synthesis of a compound of a formula 2:
is disclosed wherein
R 1 , R 2 , R 5 , R and R′ are as described above,
comprising reacting a compound of formula 1b:
with a borate and water mixture wherein the borate is represented by structural formula 1c or 1d:
wherein R and R′ are described above, in the presence of a base and a palladium catalyst to produce a compound of formula 2.
Compound 1b can be made by methods known in the art and exemplified in U.S. Ser. No. 60/056967, filed Aug. 26, 1997, Merck case number 19988PV, herein incorporated by reference.
Suitable bases include C 1-6 alkylamines such as diisopropyl amine, t-butyl amine, methylamine, hexylamine, ethylamine, triethylamine, diisopropylethylamine, trimethylamine, ethyldimethylamine, tri-n-propylamine and the like, 1,8-diazabicyclo[5.4.0]undec-7-ene (DBU), pyridine, imidazole, lutidine, collidine, 4-dimethylaminomethylpyridine, inorganic carbonates and bicarbonates such as sodium carbonate, sodium bicarbonate, potassium bicarbonate, potassium carbonate, and the like and tartrates such as potassium sodium tartrate, potassium tartrate, potassium bitartrate, sodium tartrate, sodium bitartrate and the like.
Suitable palladium catalyst include Pd(OAc) 2 , Pd(PPh 3 ) 4 PdCl 2 , PdCl 2 (PPh 3 ) 2 , PdCl 2 (CH 3 CN) 2 and Pd 2 dba 3 , and the like, wherein dba is dibenzylideneacetone.
In still another aspect of the invention a compound of formula 3 is disclosed:
wherein
R 1 represents TES, TMS or TBS, R 2 represents C 1-3 alkyl and R 5 represents PNB.
The process of the present invention is illustrated by the following generic scheme:
The 2-vinyl compound (compound 2) is synthesized from compound 1, which is readily available by Stille cross-coupling and can be suitably protected by a number of synthetic methods.
Typical conditions for the reaction involve transforming the 2-vinyl compound to its aldehyde (compound 3) using cleavage oxidation catalyzed by about 0.3 mol % to about 25 mol %, preferably about 4.0 mol % to about 12 mol % of a catalyst such as RuCl 3 , RuO 2 , K 2 OsO 4 .2H 2 O, KMnO 4 , OSO 4 or a combination thereof. About 0.5 to 15.0 equivalents, preferably 2 to 6 equivalents of oxidant is preferably added. The oxidant can be a single entity or a complex such as NaIO 4 -HIO 4 , in which case the ratio of NaIO 4 and HIO 4 ranges from about 5 to 0 to 1 to 1, respectively.
The final product may be characterized structurally by techniques such as NMR, IR, MS, and UV. For ease of handling, the final product, if not crystalline, may be lyophilized from water to afford an amorphous, easily handled solid.
The compounds of the present invention are valuable intermediates for antibacterial agents that are active against various Gram-positive and to a lesser extent Gram-negative bacteria, and accordingly find utility in human and veterinary medicine.
Many of the compounds that can be made in accordance with the present invention are biologically active against MRSA/MRCNS. In vitro antibacterial activity is predictive of in vivo activity when the compounds are administered to a mammal infected with a susceptible bacterial organism.
The invention is further described in connection with the following non-limiting examples.
EXAMPLE 1
A solution of commercially available diazo compound 1 (1.0 g), zinc chloride (2 mg) and rhodium octanoate (9 mg) in dry dichloromethane (5 mL) was refluxed for 4 h. The solution was cooled to −75° C. and diisopropylamine (0.28 mL) and triethylamine (0.10 mL) were added. After 10 min, trifluoromethanesulfonic anhydride (0.35 mL) was added keeping the internal temperature below −65° C. The reaction mixture was stirred at −75° C. for 2 h. To this solution was added a solution of Pd 2 (dba) 2 (168 mg) in dry THF (8 mL) at −75° C.
In a separate flask, vinylmagnesium chloride (15 wt % in THF; 4.8 mL) was added to a solution of triisopropylborate (0.92 mL) in dry THF (12 mL) at −5° C. The reaction mixture was aged at −5° C. for 1 h and at 22° C. for 1 h. The mixture was transferred to the above triflate solution. Water (12 mL) was added to the mixture at −40° C. The reaction mixture was aged at 0° C. for 1 h and at 22° C. for 1 h.
The reaction mixture was diluted with t-butyl methyl ether (50 mL). The organic layer was separated, washed with water (3×50 mL) and concentrated in vacuo to obtain a residue, which was chromatographed on silica gel using ethyl acetate and hexanes (1:4 to 1:2) as eluant to give 2-vinyl carbapenem 2 (484 mg) in 50.0% isolated yield as a crystalline solid.
mp: 82.0-83.0° C.
1 H NMR (250 MHz, CDCl 3 ): δ8.22 (m, 2H), 7.67 (d, J=8.7 Hz, 2H), 7.37 (dd, J=17.8 and 10.9 Hz, 1H), 5.57 (dd, J=17.8 and 1.0 Hz, 1H), 5.50 (dd, J=11.0 and 1.0 Hz, 1H), 5.46 (d, J=13.9 Hz, 1H), 5.27 (d, J=13.9 Hz, 1H), 4.25 (quint, J=6.2 Hz, 1H), 4.19 (dd, J=9.3 and 2.8 Hz, 1H), 3.40 (dq, J=9.0 and 7.5 Hz, 1H), 3.23 (dd, J=6.1 and 2.7 Hz, 1H), 1.29 (d, J=6.2 Hz, 3H), 1.22 (d, J=7.4 Hz, 3H), 0.94 (t, J=7.9 Hz, 9H), 0.60 (m, 6H)
13 C NMR (62.9 MHz, CDCl 3 ): δ172.9, 160.8, 149.0, 147.5, 142.9, 128.9, 128.1, 125.7, 123.7, 121.8, 66.0, 65.2, 59.2, 56.3, 39.0, 22.6, 16.7, 6.8, 4.9.
EXAMPLE 2
A three-necked-flask equipped with a mechanical stirrer, a 500 mL dropping funnel, a reflux condenser, a thermocouple and a nitrogen inlet was charged with propargyl alcohol (140 mL) and toluene (350 mL). The colorless solution was cooled to 0° C. and catecholborane (300 mL) was added over 45 minutes keeping the internal temperature below 20° C. Caution: vigorous hydrogen evolution! When the hydrogen evolution ceased the cold bath was replaced with a heating mantel and the solution was warmed to 70° C. The remaining catecholborane was added over 1 h and the solution was held at 110° C. for 10 h. The reaction mixture contained a 3.8:1 mixture of 3 and its regioisomer by 1 H NMR. Toluene (350 mL) was added and the solution was cooled to 5° C. at the rate of −10° C./h. A large crop of colorless crystals developed at about 80° C. The solids were collected on a frit and washed with cold (0° C.) toluene (250 mL). The filter cake was dried under nitrogen to provide 446.5 g (1.52 mol, 67.5%) of a 20:1 mixture of 3 and its regioisomer as a white solid.
1 H NMR (CDCl 3 ; 250 MHz): δ7.28-7.18 (m, 2H), 7.18-7.00 (m, 7H), 6.19 (dt, J=18.2 and 1.9 Hz, 1H), 4.88 (dd, J=3.5 and 1.9 Hz, 2 H).
13 C NMR (CDCl 3 ; 62.9 MHz): δ150.6, 148.2, 148.1, 147.8, 122.7, 122.6, 122.4, 112.4, 112.3, 112.1, 66.9.
EXAMPLE 3
A solution of diazo compound 1 (100 g), zinc chloride (200 mg) and rhodium octanoate (0.9 g) in dry methylene chloride (450 mL) was refluxed for 4 hr. Diisopropylamine (30.8 mL) and triethylamine (10 mL) were added to the reaction mixture at −75° C. After 10 min., trifluoromethanesulfonic anhydride (38.9 mL) were added to the mixture keeping the internal temperature below −65° C. The resulting triflate solution was aged at −75° C. for 2 hr.
`In a separate flask, diborate 3 from Example 2 (76 g) was stirred in a mixture of THF (120 mL), 3 M aqueous potassium carbonate (43 mL) and phosphate buffer (1.3 M, pH=7.6, 360 mL) under argon atmosphere for 2 h at 22° C.
The catalyst for this reaction was prepared as follows: To a solution of triphenylphosphine (12.5 g) in dry THF (1.2 L) was added palladium acetate (3.56 g) under argon atmosphere. The mixture was stirred at 22° C. until it became homogeneous solution (20 min). The solution was heated to 68° C. for 30 min. Prior to the coupling reaction, the solution was cooled to 22° C.
The triflate and catalyst solutions were added to the above diborate mixture under an argon atmosphere. The resulting mixture was stirred at 35° C. The reaction was complete in 1 h with an assay yield of 93%.
The reaction mixture was diluted with a mixture of ethyl acetate (1.2 L) and hexanes (300 mL) and stirred for 10 min at room temperature. The mixture was filtered through Solka-Flock. The organic layer was separated and washed water (3×500 mL). The organic layer was concentrated to about 250 mL and hexanes was added to the solution until the product crystallized. Allyl alcohol 4 (82.5 g) was isolated in 81% isolated yield as crystals. The mother liquor contained 10.2 g (10%) of 4.
1 H NMR (250 MHz, CDCl 3 ): δ8.22 (m, 2H), 7.68 (d, J=8.7 Hz, 2H), 7.31 (d, J=16.2 Hz, 1H), 6.19 (dt, J=16.2 and 5.5 Hz, 1H), 5.46 (d, J=13.9 Hz, 1H), 5.27 (d, J=13.9 Hz, 1H), 4.35-4.16 (m, 4H), 3.37 (m, 1H), 3.23 (dd, J=6.2 and 2.7 Hz, 1H), 1.49 (t, J=5.9 Hz, 1H), 1.29 (d, J=6.2 Hz, 3H), 1.22 (d, J=7.9 Hz, 3H), 0.94 (t, J=7.8 Hz, 9H), 0.60 (m, 6H).
13 C NMR (62.9 MHz, CDCl 3 ): δ172.9, 160.9, 148.7, 147.5, 143.0, 137.4, 128.1, 125.2, 123.7, 122.4, 66.0, 65.2, 63.3, 59.1, 56.4, 39.5, 22.6, 16.8, 6.8, 4.9.
EXAMPLE 4
Into a 3-L three-necked flask equipped with a mechanical stirrer and a thermal couple was charged potassium osmate dihydrate (2.61 g), 4-methylmorpholine N-oxide (34.4 g), 4-morpholineethanesulfonic acid monohydrate (84.2 g), and water (250 mL). This mixture was stirred at 30° C. until potassium osmate dihydrate dissolved. A solution of 2-allylic alcohol 4 from Example 3 (53.6 g, 93.2 wt %) in THF (500 mL) was added in the rate in keeping the temperature lower than 30° C. This solution was stirred at 30° C. for 1.5 h. The organic layer was separated and washed with brine-water (3:7, 250 ml). A mixture of THF (200 mL) and water (250 mL) was added to the organic layer and sodium periodate (36.0 g) was added to the resulted mixture. After stirring 10 min at 30° C., ethyl acetate (1 L) and water (1 L) was added. The organic layer was washed with 1 M sodium thiosulfate (2×250 mL) and brine (250 mL). To the solution was added silica gel (100 g). Evaporation of the solvent gave a dark brown residue which was filtered through a silica gel pad (50 g) using a mixture of ethyl acetate and heptane (1:6, 2 L). Evaporation of the filtrate gave 2-formyl carbapenem 5 as yellowish crystals (24.5 g, 90 wt %, 46.7% yield).
1 H-NMR (250 MHz, CDCl 3 ): δ10.4 (s, 1H), 8.24 (m, 2H), 7.67 (d, J=8.6 Hz, 2H), 5.51 (ABq, J=13.6 Hz, 1H), 5.36 (ABq, J=13.6 Hz, 1H), 4.36 (dd, J=10.5 and 3.5 Hz, 1H), 4.30 (qd, J=6.2 and 5.0 Hz, 1H), 3.51 (dq, J=10.2 and 7.3 Hz, 1H), 3.41 (dd, J=4.5 and 3.7 Hz, 1H), 1.24 (d, J=6.6 Hz, 6H), 0.94 (t, J=7.8 Hz, 9H), 0.63 (m, 6H).
13 C-NMR (62.9 MHz, CDCl 3 ): δ188.9, 172.8, 159.2, 147.8, 143.0, 141.8, 140.0, 128.4, 123.7, 66.4, 65.0, 60.9, 56.2, 38.0, 22.2, 16.2, 6.70, 4.82.
EXAMPLE 5
To a 500 mL round-bottom flask was added the aldehyde 5 from Example 4 (13.5 g) with 250 ml of dry THF. Borane THF complex (1.0 M in THF; 26.1 ml) was added via syringe at −15° C. and the resulting solution was stirred for 10 minutes. The reaction solution was quenched into a cold mixture of ethyl acetate and water (800 ml). The organic layer contained 2-hydroxymethyl carbapenem (6) in 94% yield by HPLC analysis. The organic layer was dried over magnseium sulfate and solvent switched to heptane. The solution was concentrated to ˜50 ml and the resulting crystals were collected by filtration. The cake was washed with 25 ml of heptane. The crystalline product (12 g) (89%) was isolated.
EXAMPLE 6
Into a 500 mL three-necked flask equipped with a mechanical stirrer and a thermal couple was charged potassium osmate dihydrate (75.5 mg), 2-vinyl carbapenem 2 from Example 1 (4.0 g), and phosphate buffer (pH=6.0, 2 M, 130 mL). Sodium periodate (5.3 g) was added over 5 h. Brine (100 mL) was added and then layers was separated. The aqueous layer was extracted with ethyl acetate (100 mL). The combined organic layers were concentrated to 50 mL and added slowly into a suspension of sodium borohydride (3.1 g) and zinc chloride (5.6 g) in ethyl acetate (200 mL) under 0° C. After stirred 1 h at room temperature, the suspension was filtered. Evaporation of the filtrate gave a brown oil, which was passed though a silica gel column (8 g of silica gel, hexanes and ethyl acetate=10:1). Recrystallization from a mixture of ethyl acetate and hexanes gave 6 (1.79 g, 44%). | The invention describes an improved process for synthesizing 1-β-methyl-2-hydroxymethyl substituted carbapenems as key intermediates for the synthesis of anti-MRSA carbapenem antibiotics. The synthesis eliminates the use of BU 3 SnCH 2 OH and HMPA, which are toxic substances and not amenable to industrial scale production. The novel intermediates are also within the scope of this invention.
The invention relates to the synthesis of a compound of formula 3:
wherein R 1 represents H or a suitable protecting group for an alcohol; R 2 represents H or methyl; and R 5 represents a carboxy protecting group as well as the compounds made therein. | 2 |
FIELD OF THE INVENTION
The field of this invention is general surgery, thoracic surgery, trauma and critical care.
BACKGROUND OF THE INVENTION
Chest drainage tubes are used following thoracic surgery, chest trauma or to treat certain medical conditions. The purpose of a chest tube is to remove buildup of excessive body fluids, contaminants or air from the thoracic cavity. The presence of an opening into the chest or thorax, created with or without a cannula will cause pneumothorax (collapsed lung). Negative pressure in the chest cavity is created by the chest muscles and diaphragm in order to cause lung expansion and resulting inspiration of a breath. Therefore, a hole in the chest will equalize pressure and prevent critical lung function, i.e. lung insufflation. Any cannula placed into a patient's chest cavity for drainage must be sealed to prevent pneumothorax from occurring.
Current chest drainage cannulae, also called chest tubes, drainage catheters or drainage cannulae, are flexible polymer tubes, placed into the chest cavity and extending outside the patient.
Chest drainage tubes are placed using a surgically invasive procedure. Generally, if a surgical incision into the chest has not been made, the chest tube is usually placed with the aid of an internal trocar that stiffens the chest tube and allows for easier chest wall penetration during placement. The procedure begins with a skin incision large enough to accommodate the diameter of the selected chest tube. Chest tubes are typically 8 mm to 10 mm diameter. The internal trocar, having a sharp point, is placed inside the chest tube. The pointed end of the trocar chest tube combination is pressed through the skin incision and plunged into the thoracic cavity through the muscle, fascia and fat layers of the patient, through the rib space and into the pleural cavity. The trocar is removed and the chest tube is clamped to prevent pneumothorax.
When drainage is required, the clamp is opened and fluid, air and contaminants are removed from the thoracic cavity. The fluid, air and contaminants typically are removed, forcefully, by use of external vacuum or pumping systems. The clamp is closed once drainage is completed to avoid reflux of fluid and air back into the chest cavity and possible generation of pneumothorax or influx of contaminants (i.e. infectious agents).
Placement of current chest drainage tubes is an invasive surgical procedure. With any invasive surgical procedure, there exists a risk of iatrogenic trauma to the patient. Significant training is required to safely perform these procedures and this training may not have been completed by emergency personnel who are the first line of treatment for many patients experiencing trauma.
Improved valving mechanisms would increase functionality of chest drainage tubes and overcome issues that occur with clamp application and removal. There are also fewer steps required of the medical practitioner in chest drainage when a tube with an internal valving mechanism is employed. There may also be a problem with a chest tube being pushed too far into the patient, resulting in kinking, compromised drainage and potential iatrogenic damage to internal organs.
SUMMARY OF THE INVENTION
This invention relates to a catheter, tube or cannula for draining fluid, air and contaminants from the chest and a method of placement.
The cannula of the present invention includes an internal, semi-automatic valving mechanism, which allows for fewer steps and minimizes the chance of leaving the chest tube open to atmosphere when drainage is completed. The cannula of the present invention also comprises an external movable fixation device to prevent inadvertently pushing the cannula too far into the patient. The minimally invasive placement method of the present invention is beneficial in not only the emergency setting but also in the hospital setting by reducing the chance of iatrogenic injury to the patient.
The cannula is a polymeric tube, preferably with a metal spiral winding to prevent kinking or collapse, which is fenestrated at or near the distal tip at a plurality of sites. The cannula includes an interior valve or seal, located inside the drainage lumen of the cannula, operably able to prevent reflux or efflux of fluid, air and contaminants to or from the chest. The cannula includes an intracorporeal fixation device, located internal to the patient, to prevent outward dislodgement of the chest tube from the chest. The cannula also includes an extracorporeal fixation device, located external to the patient to prevent inward movement of the chest tube.
In one embodiment, application of a vacuum at the proximal end of the cannula causes the internal valve to open thus allowing free flow of fluid, air and contaminants from the chest through the cannula and into the drainage system. The drainage system is typically a vacuum powered, water sealed suction device and collection reservoir. Removal of the vacuum causes exposure of the valve to atmospheric pressure and subsequent closure of the valve, thus reflux of fluid, air and contaminants into the chest is prevented.
Alternatively, the valve could be operated by application of positive pressure (above atmospheric) for closure of the valve and application of negative or zero pressure to open the valve. External feedback systems utilizing pressure sensors or other devices are used to ensure patient safety with the positive pressure valve closure embodiment.
In another embodiment, the internal valve is placed at the proximal end of the cannula. This valve is fabricated from a soft polymeric compound or foam with a central hole that is normally closed. Application of a mechanical force through the center of the valve, with a hollow obturator, for example, opens the valve and allows flow through the hollow obturator. Removal of the hollow obturator causes closure of the valve and prevention of reflux back into the thoracic cavity.
In yet another embodiment, the valve is a duckbill valve that passively prevents reflux back into the thoracic cavity while allowing drainage from the chest cavity under application of appropriate pressure drop across the valve. Such pressure drop can occur from an increase of intrapleural pressure caused by buildup of fluids or by application of a vacuum to the outlet side of the valve.
In all embodiments, the valve systems are, preferably, integral to the cannula and unable to be separated from the cannula when, for example, the patient rolls over and stresses the connection.
The drainage cannula of the present invention includes an intracorporeal fixation or retaining device that prevents the cannula from being removed inadvertently from the patient. This intracorporeal device is, for example, an elastomeric or inelastic (i.e. angioplasty-type) balloon affixed to the exterior surface of the cannula. The balloon is passed inside the chest cavity and is inflated with sterile liquids or air to prevent withdrawal through the hole or wound in the chest wall. Inflation typically occurs using a balloon inflation lumen in the cannula, inflation ports between the lumen and the balloon, and an inflation device external to the cannula.
Additionally, the drainage cannula of the present invention includes an extracorporeal fixation device that may comprise one or more clips that are affixed to the exterior of the cannula in a movable fashion. These clips are, preferably, located proximally to the internal fixation device or balloon. They may be moved against the chest wall and frictionally engaged to the cannula shaft to prevent the cannula from being forced too far into the patient. Such extracorporeal fixation devices could be retrofitted to existing chest tubes to improve the functionality of existing chest tubes.
The chest drainage tube of the current invention is placed in a minimally invasive procedure. Placement is accomplished by first performing a surgical skin nick and then placing a hypodermic needle into the pleural space of the patient at the site of the skin nick. A J-tip guidewire is placed through the hypodermic needle and the hypodermic needle is removed. A percutaneous access device or trocar is placed into the central lumen of the chest tube and over the guidewire and routed into the pleural space.
In a further embodiment, the cannula is steerable. This is accomplished by use of a malleable, bendable trocar that can be shaped prior to insertion into the patient. In another embodiment, steerability is obtainable by heat setting the cannula with a curved shape. Axially moving a rigid straight trocar into the bent portion of the cannula from the proximal end causes the curved shape to straighten out. This controllable bending is useful for negotiating tight turns in the patient. In another embodiment, steerability may be obtained using actuators on the surface or within the interior of the cannula to force bending of the cannula. These actuators are typically electrically powered. An actuator comprises electrical leads, a power source, a compressible substrate, and shape memory materials such as nitinol. Such actuators may be distributed along the length of the cannula. The actuators may be placed so as to oppose each other. Opposing actuators are activated one at a time and not simultaneously.
The combination of minimally invasive placement and reduced steps to operate the chest drainage tube will benefit patients and medical practitioners by reducing errors, minimizing trauma, increasing ease of use, and improving patient outcomes.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates the cannula, according to aspects of an embodiment of the invention;
FIG. 2 illustrates a cross-section of multi-lumen tubing used in fabrication of the cannula, according to aspects of an embodiment of the invention;
FIG. 3A illustrates a trocar useful for surgical placement of the cannula, according to aspects of an embodiment of the invention;
FIG. 3B illustrates the cannula with the trocar of FIG. 3A inserted therein, according to aspects of an embodiment of the invention;
FIG. 4A illustrates the percutaneous access trocar, guidewire and hollows needle for the method, according to aspects of an embodiment of the invention;
FIG. 4B illustrates the cannula with the percutaneous access trocar of FIG. 4A inserted therein, according to aspects of an embodiment of the invention;
FIG. 5A illustrates th cannula with the selectively openable, slotted distal drainage apparatus, wherein the slots are closed, according to aspects of an embodiment of the invention;
FIG. 5B illustrates th cannula with the selectively openable, slotted distal drainage apparatus, wherein the slots are opened, according to aspects of an embodiment of the invention; and
FIG. 5C illustrates a vertical cross section of the proximal end of the cannula, according to aspects of an embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 illustrates a cannula, tube or catheter 10 of the present invention. The catheter 10 comprises a manifold or hub 12 , a valve or seal 14 , an extracorporeal fixation device 16 , an intracorporeal fixation device 18 , a plurality of drainage holes 20 , and a length of multi-lumen tubing 22 . In addition, the catheter 10 optionally comprises a valve housing 15 . The manifold 12 comprises a drainage adapter or fitting 24 , a valve-enabling adapter or fitting 26 , and an intracorporeal fixation-enabling adapter or fitting 28 . In this preferred embodiment, the intracorporeal fixation device 18 is a balloon, and the intracorporeal fixation-enabling adapter 28 is a balloon inflation adapter or fitting. The multi-lumen tubing preferably comprises a stiffening wire 30 .
FIG. 2 illustrates a cross-section of the multi-lumen tubing 22 . The multi-lumen tubing 22 comprises a drainage lumen 32 , a valve enabling lumen 34 , an intracorporeal fixation-enabling lumen 36 , and a wall 38 . In this preferred embodiment, the intracorporeal fixation-enabling lumen 36 is an inflation lumen. There is no communication between the drainage lumen 32 , the inflation lumen 36 and the valve enabling lumen 34 . The tubing material may be selected from any polymer such as, but not limited to, polyvinyl chloride, polyurethane, polyethylene and the like. The tubing 22 is, preferably, transparent or semi-transparent. At least a portion of the tubing 22 is preferably stiffened with a helical winding of material such as stainless steel, nitinol and the like. The stiffening 30 could also be created using corrugations in the tubing 22 or by addition of a strong polymer such as glass-filled polycarbonate instead of the metal helical winding. The stiffening member 30 serves the purpose of preventing collapse of the cannula 10 when vacuum is applied to the drainage lumen 32 . The stiffening member 30 also serves to prevent kinking when the cannula 10 is bent around a tight radius.
Referring to FIGS. 1 and 2, the manifold 12 connects to the proximal end of the length of multi-lumen tubing 22 such that the drainage adapter 24 connects to the drainage lumen 32 , the balloon inflation adapter 28 connects to the inflation lumen 36 , and the valve-enabling adapter 26 connects to the valve-enabling lumen 34 . There is no communication between the drainage adapter 24 , the balloon inflation adapter 28 , and the valve-enabling adapter 26 . The manifold 12 is typically molded from polymer, such as polyvinyl chloride, polycarbonate, acrilonitrile butadiene styrene (ABS), or the like.
The distal end of the multi-lumen tubing 22 comprises the plurality of drainage holes 20 . The drainage holes 20 connect the exterior of the catheter 10 with the drainage lumen 32 . The holes 20 are of sufficient size and quantity to allow for passage of fluid, thrombus and debris that might need to be removed from the chest cavity. The plurality of drainage holes 20 and the drainage lumen 32 may further be coated with an anti-thrombogenic coating of material such as, but not limited to, heparin.
The valve or seal 14 is preferably located in the drainage lumen 32 of the catheter 10 , between the manifold 12 and the drainage holes 20 . Alternatively, the valve or seal 14 may be mounted proximal to the manifold 12 or inside the manifold 12 . If the optional valve housing 15 is used, the housing 15 encircles the catheter 10 and is open to the drainage lumen 32 . The valve 14 sets inside the housing 15 . The intracorporeal fixation balloon 18 is located on the outside surface of the multi-lumen tubing 22 , between the manifold 12 and the drainage holes 20 , approximately 2 cm to 40 cm from the most proximal drainage hole. More preferably, the intracorporeal fixation device or balloon 18 is located between 5 cm and 20 cm from the most distal drainage hole. The balloon 18 is located over a balloon inflation port that allows communication between the balloon 18 and the inflation lumen 36 . The extracorporeal fixation device 16 is slidably located on the outside of the multi-lumen tubing 22 , between the manifold 12 and the intracorporeal fixation balloon 18 .
When the catheter 10 is in use, the manifold 12 connects to a drainage system through the drainage adapter 24 . The drainage adapter 24 is typically larger in diameter than the balloon inflation fitting 28 or valve-enabling fitting 26 . The drainage adapter 24 is capable of being connected to the gravity-fed, pump-driven or vacuum-fed drainage system and is most typically a ⅜ inch to ½ inch diameter hose barb. Standard drainage systems generally comprise a connector, a length of tubing and a reservoir. Optionally, a vacuum pump may be connected to the reservoir.
The manifold 12 also connects to an inflation system through the balloon inflation adapter 28 . The balloon inflation adapter 28 is typically a female luer fitting but may be any fluid-tight fitting suitable for use with an inflation syringe or the like. The standard balloon inflation system comprises a syringe, a volume of balloon inflation fluid such as sterile saline, air or radiopaque media, and a valve or stopcock. Additionally, the balloon inflation system could comprise a device, such as a jackscrew, to advance or withdraw a plunger on the syringe using mechanical advantage.
Additionally, the manifold 12 connects to a valve enabling system through the valve-enabling adapter 26 . The valve-enabling adapter 26 is, preferably, a female luer lock adapter, but could be another type of fluid-tight connection such as a threaded swage-lock, or the like.
FIG. 3A illustrates a trocar 40 useful for surgical placement of the cannula 10 of the present invention. The trocar 40 comprises a plunger 42 , a body 44 and a pointed tip or needle 46 . FIG. 3B shows the trocar 40 inserted into the drainage lumen 32 of the catheter 10 . The needle 46 extends out from the distal tip of the catheter 10 and the plunger 42 extends out from the proximal end of the catheter 10 . The internal trocar 40 stiffens the chest tube 10 and allows for easier thoracic penetration during placement. The internal trocar 40 is typically made from metal or polymer. The internal trocar 40 is, optionally, fabricated to be malleable. Medical personnel make a skin incision large enough to accommodate the diameter of the chest tube 10 . Chest tubes 10 are typically 8 mm to 10 mm diameter. The pointed needle 46 of the trocar chest tube combination 40 , 10 is pressed against the skin incision. Medical personnel push the plunger 42 to force the needle 46 into the thoracic cavity through the muscle, fascia and fat layers of the patient, through the rib space and into the pleural cavity. The trocar 40 is removed and the chest drainage tube 10 is in place. Fixation devices are enabled at this point.
FIGS. 4A and 4B illustrate a more preferred method of chest drainage tube placement. FIG. 4A illustrates a kit 48 comprising a hollow needle 50 , a guidewire 52 , and a tapered, flexible trocar 54 . The trocar 54 comprises a tip 56 and a handle 58 . First, the hollow needle 50 is inserted into the chest between the ribs, through the skin, fat, intercostal muscle, fascia and pleura. Next, the guidewire 52 is inserted through the needle 50 into the chest cavity to the desired location of the distal tip of the cannula 10 or beyond. Preferably, the guidewire 52 has a J-tip configuration at its distal end.
As shown in FIG. 4B, the tapered, flexible trocar 54 is inserted into the cannula 10 such that the tip 56 of the trocar 54 extends through the distal tip of the cannula 10 and the handle 58 of the trocar 54 extends through the proximal end of the cannula 10 . The needle 50 is removed and the flexible trocar-cannula combination 54 , 10 is threaded over the proximal end of the guidewire 52 . The flexible trocar-cannula combination 54 , 10 is moved over the guidewire 52 and inserted through the hole in the chest formed by the needle 50 . The tapered trocar 54 expands the chest hole and allows passage of the larger diameter back section of trocar 54 and cannula 10 into the patient. The trocar 54 and cannula 10 are advanced to the desired intrathoracic site along the route described by the guidewire. Once the tip 56 of the trocar 54 is in the desired location, the trocar 54 is removed from the proximal end of the cannula 10 . This method of cannula placement using the flexible, tapered trocar 54 requires a smaller incision than a standard trocar 40 . The incision may even be a percutaneous stick. The additional benefit is that the flexible trocar 54 and cannula 10 follow the path created by the guidewire 52 and route to the desired location without damaging tissue inadvertently. The tapered, flexible trocar 54 is typically fabricated from polymers such as PVC or polyethylene. The tapered, flexible trocar 54 exhibits column strength but is bendable. The tapered, flexible trocar 54 is able to flex easily along the path described by the guidewire 52 .
Referring to FIGS. 1 and 2, once the chest drainage tube 10 is placed in the patient's chest, the intracorporeal fixation balloon 18 is inflated. Balloon inflation fluid from the balloon inflation system is injected into the balloon inflation lumen 36 through the balloon inflation fitting 28 . The balloon inflation fluid travels through the balloon inflation lumen 36 to the balloon inflation port. The balloon inflation fluid travels through the balloon inflation port into the balloon 18 , inflating the intracorporeal fixation balloon 18 . The valve or stopcock on the balloon inflation system is closed to maintain the balloon 18 in the inflated configuration. The stopcock remains attached to the balloon inflation adapter to prevent unwanted balloon deflation. The balloon 18 is inside the patient's chest and is larger than the chest incision. The balloon 18 prevents the chest drainage tube 10 from inadvertently being pulled out of the patient. The balloon inflation fluid is selectively drained from the intracorporeal fixation balloon 18 by opening the stopcock to deflate the balloon 18 and allow the cannula 10 to be removed from the patient's chest.
In another embodiment, the intracorporeal fixation device 18 is an expandable region of cylindrical material with longitudinal slits or slots, a distal ring and a proximal ring. The rings and interconnecting slotted cylinder are disposed coaxially and concentrically around the cannula 10 shaft. The distal ring is connected to a control rod routed through the intracorporeal fixation lumen 36 to a control handle on the proximal end of the cannula 10 . When the cannula 10 is in place, the control rod is pulled, causing the distal ring of the intracorporeal fixation device 18 to pull along the cannula 10 shaft, toward the proximal ring. This causes the slit cylinder to collapse in length and the cylinder material between slits expands in diameter, forming a starburst pattern. A locking mechanism at the proximal end of the cannula 10 keeps the control rod from moving once the intracorporeal fixation device 18 is opened in the desired position. This system functions like a moly-bolt or drywall anchor to keep the cannula 10 from being removed from the chest inadvertently. The control rod may be unlocked and the distal ring advanced distally to contract the anchor around the cannula 10 so the cannula 10 may be removed from the patient. Optionally, holes or openings in the cannula 10 that connect with the drainage lumen 32 may be disposed underneath the slots or slits of the intracorporeal fixation device 18 thus providing additional chest drainage ports when the intracorporeal fixation device 18 is in the open position.
In addition to enabling the intracorporeal fixation device 18 , the extracorporeal fixation device 16 is also enabled once the catheter 10 is in place in the patient's chest. The extracorporeal fixation device 16 is located outside the chest and is disabled to allow the fixation device 16 to slide over the exterior of the catheter 10 , into place, against or close to the patient's skin. The extracorporeal fixation device 16 is enabled and forcibly stops sliding, preventing the chest drainage tube 10 from inadvertently being pushed farther into the patient's chest.
In a preferred embodiment, the extracorporeal fixation device 16 is a lockable clip device. When the lock is open, the extracorporeal fixation device 16 slides over the catheter 10 . When the desired location on the catheter 10 is reached, the lock is closed and the extracorporeal fixation device 16 engages the catheter 10 with enough force to make dislodgement of the fixation device 16 relative to the cannula or catheter 10 difficult, but with insufficient force to crimp or restrict the catheter 10 or the lumens 32 , 34 , 36 . The clip 16 is considerably larger than the diameter of the catheter 10 and the incision in the chest and, preferably has atraumatic rounded edges where it contacts the patient. At least one lateral dimension of the external fixation device or clip 16 is generally between 0.25 and 2 inches. More preferably, the external fixation device or clip 16 is between 0.5 and 1.0 inches in lateral dimension.
In another embodiment, the extracorporeal fixation device 16 is an inflatable balloon. The extracorporeal fixation balloon 16 may be inflated from the balloon inflation lumen 36 used to inflate the intracorporeal inflation balloon 18 . Alternatively, the extracorporeal inflation balloon 16 may be inflated from an additional balloon inflation lumen.
In yet another embodiment, the extracorporeal fixation device 16 is an opposably engaged spring clip, which encircles the catheter 10 . When the spring is compressed, the clip 16 is slid to the desired location on the catheter 10 . When the pressure on the spring is released, the clip 16 is locked into place on the catheter 10 . A similar type of spring clip is used to secure a drawstring on a sleeping bag. A further embodiment of the extracorporeal fixation device 16 is a rocking clip that slides when it is tilted relative to the lateral axis of the cannula 10 and locks when it is in the plane perpendicular to the axis of the cannula 10 .
In another embodiment, the extracorporeal fixation device 16 comprises a penetrable polymeric tab to allow suture passage and attachment of the extracorporeal fixation device 16 to the patient's skin with suture. The distal side of the extracorporeal fixation device 16 may comprise an adhesive layer to facilitate not only fixation but provide a contamination barrier at the entry site. The extracorporeal fixation device 16 optionally comprises a hole located somewhere on its structure, through which suture may be passed to facilitate attachment to the patient's skin.
In yet another embodiment, the extracorporeal fixation device 16 slides over a plurality of bumps or detents on the cannula 10 exterior surface. These bumps or detents serve to prevent axial motion of the extracorporeal fixation device except under substantial selective manual force. The extracorporeal fixation device 16 may additionally have a ratcheting mechanism that allows for axial motion toward the patient but prevents motion in the reverse direction away from the patient.
The extracorporeal fixation device is useful to retain not only drainage tubes but also any type of catheter in place in the patient.
Once the catheter 10 is placed in the patient's chest, the valve 14 , which is normally closed, prevents pneumothorax from occurring. The normally closed valve 14 seals the drainage lumen 32 . When the medical personnel require chest drainage, the valve 14 is enabled or opened to allow fluid, air and contaminants to drain from the chest drainage tube 10 .
In one embodiment, the valve-enabling lumen 34 is connected through the valve-enabling adapter 26 to a vacuum system. The typical vacuum system is operated by an electrical vacuum pump and regulator to maintain a low level vacuum of 1 to 100 mm Hg. Preferably, the vacuum is maintained at a level of 1 to 20 mm Hg. When the vacuum system is activated, a vacuum is drawn through the valve-enabling lumen 34 and the valve 14 opens. Stopping the vacuum system causes the valve 14 to close and seal the drainage lumen 32 .
The preferred vacuum activated valve embodiment 14 is one or more balloons mounted within the drainage lumen 32 of the cannula 10 . More preferably, the balloons 14 are exposed to the drainage lumen 32 but reside within the optional valve housing 15 that is larger than the diameter of the drainage lumen 32 . The collapsed balloons 14 reside within the housing 15 and do not impinge on the drainage lumen 32 where they could impede passage of the trocar 40 or 54 . The balloons 14 are maintained in their collapsed state and out of the drainage lumen 32 by application of a vacuum through the valve-enabling adapter 26 and the valve-enabling lumen 34 . An optional stopcock on the valve-enabling adapter 26 is closed to maintain the vacuum until it is desired to close the drainage lumen seal 14 . The valve housing 15 is fabricated, preferably, from transparent materials in order to allow for visualization of valve function and verification of drainage lumen patency. The balloons 14 are made with open cell foam. Such open cell foams are typically made from polyurethane materials and the spaces between the cells in the foam interconnect. The skin or surface of the balloon 14 is a fluid impermeable, elastomeric material such as latex, polyurethane, silastic and the like.
The balloons 14 are inflated, thus closing the valve 14 , by resilient expansion of the foam after fluid is allowed to flow back into the collapsed balloons. This may be done by removal of the vacuum or by opening the stopcock. When the valve 14 is closed, drainage through the drainage lumen 32 stops and the chest opening is sealed. The valve 14 is opened by application of a vacuum to the valve enabling lumen 34 . The vacuum system can be operably connected to the same vacuum system used for drainage of the thorax. In this way, the valve 14 automatically opens when drainage is activated.
Other valve embodiments 14 include balloons that are normally deflated and open. These valves 14 require that positive pressure be applied to inflate the balloons and occlude the drainage lumen 32 . Removal of the pressure or application of a vacuum causes the balloons to deflate and the valve 14 to open. Such valves 14 do not require the use of open cell foam cores but may require external devices to monitor drainage lumen parameters and ensure patient safety.
In another embodiment, the valve or seal 14 is made from a soft rubber or polymer. A central hole, slit or cross in the valve 14 allows for generation of potential space in this normally closed structure. In this embodiment, insertion of a hollow obturator through the valve-enabling adapter 26 and the central hole, slit or cross opens the valve 14 , permitting fluid, air and contaminants to pass through the hollow obturator.
In yet another embodiment, the valve or seal 14 is a duckbill or one-way valve permitting fluid, air and contaminants to flow from the chest but not permitting introduction of air into the chest. When the trocar 40 or 54 is advanced into the cannula 10 , the valve leaflets are moved into the open position to permit passage. This operation may be performed manually or automatically when trocar 40 or 54 insertion is required. The duckbill valve is typically fabricated from soft polymer materials such as silicone rubber, polyvinyl chloride, polyurethane and the like. The duckbill valve is preferably coated with materials such as heparin or silicone that prevent thrombosis and prevent unwanted permanent sealing of the valve leaflets.
FIG. 5A, FIG. 5B, and FIG. 5C illustrate another embodiment of the drainage holes 20 at the distal end of the catheter 10 . FIG. 5A shows the catheter 10 comprising a knob, lever, or handle 64 , a lock 66 , a control rod 72 , and a sleeve 68 . The sleeve 68 comprises a series of longitudinal slits or slots 60 and a rigid ring 62 . The proximal end of the sleeve 68 is affixed to the catheter 10 and the distal end of the sleeve terminates in the rigid ring 62 that slides over the catheter 10 . The sleeve is located over the plurality of drainage holes 20 at the distal end of the catheter 10 . The slits or slots 60 are disposed circumferentially around the sleeve 68 . The sleeve 68 is located approximately 20 cm or less from the distal end of the tubing 22 and is preferably located 10 cm or less from the distal end of the tubing 22 . The slots 60 are approximately 10 cm or less long and preferably 5 cm or less long. The slits or slots 60 are approximately 90 degrees apart and are preferably 45 degrees apart. The rigid ring 62 is operably attached to a control rod 72 running through one of the lumens of the multi-lumen tubing 22 and extending to the proximal end of the cannula 10 . As shown in FIG. 5C, the control rod 72 is terminated at the proximal end of the cannula 10 with the knob, handle or lever 64 for manual activation. In FIG. 5A, the slots 60 are closed.
FIG. 5B shows the distal tip of the cannula 10 when the control rod 72 is retracted and the slots 60 are open. As the control rod 72 is retracted proximally, the distal ring 62 moves proximally, and the slits or slots 60 expand radially and increase their opening size, thus exposing the drainage holes 20 and providing drainage. The control rod 72 may serve an additional purpose of activating the intracorporeal fixation device 18 . The lock 66 at the proximal end of the cannula 10 causes the control rod 72 to maintain its position until reversal is desired. The optional lever 64 provides mechanical advantage and makes it easier to move the control rod 72 .
In another embodiment, the slots 60 are located in the wall 38 of the multi-lumen tubing 22 and connect the exterior of the catheter 10 with the drainage lumen 32 , replacing the drainage holes 20 . As the control rod 72 is retracted proximally, the slits or slots 60 expand radially and increase their opening size, thus providing drainage.
In a further embodiment, the cannula 10 of the present invention comprises at least one flexible control rod 72 extending from the distal tip of the cannula 10 to the proximal end of said cannula 10 . The control rods 72 are slideably disposed within one of the lumens of the multi-lumen tubing 22 . The control rods 72 are disposed off-center and terminate at or near the proximal end of the cannula 10 with a handle. The control rods 72 are fabricated from wire, polymer fiber or other flexible material. The cannula 10 further comprises an area of increased flexibility proximal to the distal attachment point of the control rod 72 to the cannula 10 .
By withdrawing the control rod or rods 72 proximally, the cannula tip may be made to bend in a controlled direction in the area of increased flexibility. Such selective steerability is useful in advancing the cannula 10 through tortuous anatomy.
Alternatively, the cannula 10 of the present invention comprises a plurality of shape-memory actuators disposed longitudinally along the flexible region of the cannula. The shape-memory actuators are made from nitinol wire or from nitinol deposited over a flexible corrugated substrate, typically silicone rubber. The nitinol actuators are electrically wired through one or more of the cannula lumens to the proximal end of said cannula 10 . An electrical power source selectively connected to the wires at the proximal end of the cannula 10 causes heating of the nitinol wires and activation of shape-memory properties, which expand or contract the nitinol. Such controllable expansion or contraction of the nitinol causes the cannula 10 to experience localized forces that further cause the cannula 10 to bend and to be steerable.
The cannula 10 of the present invention is useful during or after many thoracic surgeries and will benefit many patients in the emergency setting. The system is easier to place in the patient than standard chest drainage tubes and may be placed by personnel with less training than physicians (e.g. paramedics). The system is less likely to be misused than standard chest drainage tubes.
The cannula 10 of the present invention may be used for abdominal drainage, thoracic drainage, peritoneal dialysis and other procedures. The invention is not limited solely to thoracic procedures but to general mammalian body cavity drainage and/or catheterization.
The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is therefore indicated by the appended claims rather than the foregoing description. All changes that come within the meaning and range of equivalency of the claims are to be embraced within their scope. | The present invention describes a device for placement in the thoracic cavity of a patient. The device is a cannula, tube or catheter for chest drainage. The device serves as a conduit for drainage of excessive fluid or air buildup in the chest to a receptacle outside the body. The device also serves to prevent influx of fluid or air into the chest cavity, thus preventing pneumothorax or infection. The device incorporates systems for anchoring the chest drainage cannula to the chest. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to an apparatus and method for cleaning fluid lines and, in particular, to an improved in-line manifold which controls the flow of cleaning liquid causing a pulsing action of an atomized mixture of cleaning liquid and air through the fluid lines.
2. Description of Prior Art
Fluid lines are widely employed for carrying fluid through automobile air conditioning systems, automatic transmission systems, transmission air cooler heat exchanger systems and various hydraulic systems in general. A major problem with these fluid lines is that they become partially or completely clogged and contaminated. The problem is often so serious as to require removal of the entire system in order to flush out the fluid lines with a cleaning liquid such as a solvent. Usually, such cleaning is performed by introducing a cleaning solvent such as mineral spirits or other compounded cleaning solvent into the lines.
Many of the various methods of cleaning and unclogging such fluid lines have proven to be time consuming, ineffective or incomplete, and expensive. Also, there is a problem with the safe collection of the used solvent and of filtering and reuse of it which is an additional expense to service shops.
SUMMARY OF THE INVENTION
It is an object of this invention to provide a new and improved apparatus and method for cleaning fluid lines.
It is another object of this invention to provide an improved apparatus for cleaning fluid lines that is relatively simple and safe to use.
It is further object of this invention to provide novel air and liquid manifold mounted on a cleaning liquid tank which supplies cleaning liquid and air to flush the fluid lines.
It is another further object of this invention to provide a drain system to collect the contaminated cleaning liquid for reuse or disposal and filter the vapors emitted from the solvent.
It is another further object of this invention to provide a method of cleaning the fluid lines by means or a rapid pulsing atomized cleaning liquid and air.
Other objects and advantages or this invention wilL be apparent from the following.
According to one aspect of the present invention, an apparatus for cleaning fluid lines is provided which includes a source of compressed air controlled by an air valve which is operatively connected to a unique air and liquid manifold operatively mounted on an enclosed cleaning liquid tank. A flush hose carries atomized cleaning solution and air from the outlet of the manifold tank system into and through the fluid lines being cleaned. A drain hose carries contaminated cleaning liquid from the outlet of the fluid lines into a drain tank having a hose barb, an atomized solvent defuser and air filter therein to separate the cleaning liquid for reuse or disposal.
The unique air and liquid manifold of the present invention includes the air valve which controls the flow of air into a main air chamber through which compressed air simultaneously enters openly communicated upstream branch air passage member transversely extending therefrom and an openly communicated downstream air passage member forwardly extending therefrom. The upstream air passage member has a predetermined calibrated sized air bleed orifice which communicates with the cleaning liquid tank and critically restricts the flow of air into the tank by means of its calibrated size. This critical restriction of air through the calibrated air bleed orifice causes only a small increase in the air pressure in the tank which gradually increases to force the cleaning liquid up a vertical drop tube in the tank into an openly communicated cleaning liquid receiving cavity and into an openly communicated downstream liquid passage transversely extending longitudinally therefrom in the manifold. A shut-off valve is operatively positioned along the length of the downstream liquid passage to control the downstream flow of cleaning liquid in the manifold. At its outlet end, the downstream liquid passage member is integrally connected and openly communicated with downstream cleaning liquid interior tube having a bore which carries cleaning liquid and which, for most of its length, extends longitudinally through the downstream air passage, longitudinally through a rear air channel of a threadedly connected venturi hose barb and terminating within a restricted diameter sized air and liquid front channel of the venturi hose barb. Said hose barb is secured to said downstream air passage member so that part of said rear air channel and the entire air and liquid front channel of said hose barb project beyond the exterior edge of said manifold. A flush hose is attached to the exterior surface of said venturi portion which carries the cleaning liquid and air to the fluid lines being cleaned from said hose barb.
When compressed air flows into the larger diameter downstream air passage, it flows around the exterior of the liquid interior tube through the larger diameter rear air channel and into said restricted diameter front channel of said venturi hose barb with increased velocity. As the air flows with increased velocity through said restricted front channel, venturi action occurs at the terminal end of said interior tube increasing the cleaning liquid flow from said cleaning liquid tank through the liquid flow system, through the cleaning liquid interior tube. The cleaning liquid flowing from the interior tube becomes an atomized mixture with the compressed air. Concurrently with the increased flow of cleaning liquid through the liquid system, the air passing through said air bleed orifice causes a small gradual increase in the air pressure in said cleaning liquid tank forcing cleaning liquid up the said drop tube through the liquid carrier system and interior tube. As the cleaning fluid is forced from said cleaning liquid tank with increased velocity, a small reduction in air pressure occurs in said tank hesitantly interrupting the flow of cleaning liquid up said drop tube until air pressure immediately builds up again in said tank. The continuous rising and falling pressure in said tank resulting from the cleaning liquid intermittently leaving said tank causes a rapid pulsing action for the cleaning liquid through the system and as it enters said hose and enters the fluid lines to be cleaned. This pulsing action increases the ability of the apparatus to dislodge and remove from the fluid lines being cleaned particles and debris which would not be removed by a constant flow of cleaning liquid.
Another embodiment of the present invention is a drain system to collect the used cleaning liquid for reuse or disposal. In this embodiment, used atomized cleaning liquid and air exiting the flushed fluid lines are directed through a drain hose to a drain container through a drain hose barb and elbow to a liquid diffuser where the spent cleaning liquid is collected.
DETAILED DESCRIPTION OF THE DRAWINGS
FIG. 1 is a view of one embodiment of the invention showing partly in section the entire arrangement of the apparatus for cleaning fluid lines and collecting contaminated cleaning fluid.
FIG. 2 is a perspective view of a preferred embodiment of the invention showing the novel air and liquid manifold.
FIG. 3 is a sectional bottom view showing the novel air and liquid manifold.
FIG. 4 is a sectional top view showing the novel air and liquid manifold.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, there is illustrated generally a preferred embodiment of the invention showing the overall arrangement of the apparatus for cleaning contaminated fluid lines and for collecting and filtering the contaminated cleaning liquid or solvent for reuse or disposal. The apparatus of this embodiment comprises air and liquid manifold 10 communicably connected to the top of enclosed cleaning liquid or solvent tank 12 for supplying compressed air to the tank and removing cleaning liquid therefrom. The compressed air is supplied to the tank above the cleaning liquid, such as solvent 14 for example mineral spirits, in the bottom of the tank. Compressed air hose 16 delivers compressed air from a compressed air source, not shown, through a threadedly connected quick disconnect nipple or similar device to threadedly connected air valve 18 whereby said air flows through the air flow system in the manifold to the flush hose 20. Drop tube 22 is connected at its upward end in open communication to the manifold attached to the top of the tank. The opposite end of drop rude descends into the solvent in the tank wherein the solvent is forced up said tube into the solvent flow system manifold and into connected flush hose 20. A description of the air and solvent flow in the manifold causing a pulsing action of an atomized mixture of solvent and air will be discussed relative to FIGS. 2, 3 and 4.
As seen in FIG. 1, flush hose 20 carries the atomized mixture of solvent and air to the inlet of the fluid lines to be cleaned such as in a heat exchanger 24. The pulsing action of the atomized solvent and air mixture passes through the fluid lines and removes the contamination therefrom. One end of return hose 26 is attached to the outlet of heat exchanger 24 and carries the flushed contaminated atomized solvent and air mixture from the cleaned fluid lines to drain container 28. The opposite end of return hose 26 is connected to an atomized solvent defuser 30 where the solvent is separated and collected at the bottom of the drain container. An activated charcoal filter 32 shown attached to the top exterior of the container and communicably disposed within the interior removes impurities from the air passing out of the container. In operation of the unique air and solvent manifold embodiment of the invention, depicted in FIGS. 2, 3 and 4, the outlet end of compressed air hose 16 is releasably attached to the inlet of manual shut off air valve 18 which threadedly connects into main air chamber passage 34 through the manifold threaded side inlet. The main air chamber passage extends partially across the width of the manifold to terminally and openly connect with opening 37 downstream of air passage 36 and to intersect openly with upstream branch air passage 38 and safety relief branch air passage 40 transversely extending from each side crosswise midway along its length. The upstream branch air passage 38 has a predetermined calibrated sized air bleed orifice 42 which communicates with solvent tank 12 when attached to the tank as in FIG. 1. The size of orifice 42 is calibrated to restrict the flow of compressed air into the air space above the solvent in the tank. By limiting the flow of air through the orifice into the tank, there is permitted only a gradual small increase in the air pressure occurring in the air space in the tank which small increase is sufficient to force the solvent up drop tube 22 into the manifold. The predetermined calibrated size of orifice 42 in combination with other features of the apparatus to be discussed is a major contributing link of the unique and efficient cleaning operation of the apparatus.
The upward end of drop tube 22 is openly connected to solvent receiving cavity 44 in the interior of the manifold which is openly communicated with downstream solvent passage 46 transversely extending longitudinally therefrom. Downstream liquid passage 46 has a manual one quarter turn shut-off valve 48 positioned midway along its length which opens and closes the passage to selectively regulate the downstream flow of solvent through the manifold. Shut-off valve 48 is releasably and frictionally secured through retainer ring recess 50 in the manifold in liquid-tight fashion. The shut-off valve operatively controls the flow of solvent by turning the valve handle 52 to the open or closed position. The flow of solvent from solvent tank up through drop tube 22, receiving cavity 44 and downstream solvent passage 46 is interrupted and stopped when shut-off valve handle 52 is turned to the shut-off position.
The outlet end of downstream solvent passage 46 is integrally and openly connected with downstream solvent interior tube 54 having the same inside diameter as solvent passage 46. Interior tube 54 extends longitudinally through interior opening 37 of downstream air passage 36, through rear air channel 56 and terminates at its tip end 55 partway within the restricted diameter forward air and solvent channel 60 of hose barb 58. The outside diameter of interior tube 54 is substantially smaller than the opening 37 of downstream air passage 36 and the inside diameter of rear air channel 56 but is only slightly smaller than the inside diameter of front air and solvent channel 60 of hose barb 58 because of the restricted diameter of the air and solvent channel 60. Thus, a relatively large volume annular air flows in the interior opening 37 of air passage 36 and air channel 56 around the exterior surface of interior tube 54 which passes through the interior opening 37 of air passage 36 and air channel 56. However, only a relatively small volume annular air having an increased velocity flows in restricted front channel 60 around the exterior surface to tip end 55 of interior tube 54.
The hose barb 58 as seen in FIGS. 2, 3 and 4 is threadedly secured to the female threaded outlet end of downstream air passage 36 creating interior opening 37 and causing the front part of rear air channel 56 and all of forward restricted channel 60 of the hose barb and the front section of interior tube 54 to project beyond the outlet end side of the manifold. Venturi flush hose 20 attaches to the ridged exterior surface of hose barb 58 encompassing flush nozzle 74 of restricted channel 60 to carry atomized mixture of solvent and air from the manifold to the fluid lines to be cleaned. Venturi flush hose 20 nay be attached by the hose barb by push lock means or other attachment.
In the operation of the apparatus, compressed air flows from air hose 16 to be regulated by air valve 18 into main air chamber 34. The compressed air passing through air chamber 34 simultaneously flows through the branch upstream air passage 38, branch safety relief air passage 40 and into downstream air passage 36. Compressed air flowing from branch air passage 38 passes through calibrated bleed orifice 42 which limits the flow of air into the air space above solvent 14 in solvent tank 12. The restricted air flow passing through calibrated air bleed orifice 42 causes only a gradual small increase in the air pressure in solvent tank 12 which increases sufficiently to force the solvent up vertical drop tube 22. The solvent flowing upward in drop tube 22 flows into solvent receiving cavity 44 and into downstream solvent passage 46. Shut-off valve 48 such as a one quarter turn shut off valve or similar device is operatively positioned close to the outlet end of downstream solvent passage 46 and controls the flow of solvent through the manifold by turning the valve handle 52 to the open or closed position. When shut-off valve 48 is in the open position, the solvent flows from downstream solvent passage 46 into solvent interior tube 54 to the terminal end tip 55 of the interior tube terminating partway within restricted forward channel 60 of venturi hose barb 58.
Concurrently with the above operation, compressed air is flowing through the large diameters of downstream interior opening 37 of air passage 36 and forward air channel 56 wherein the air flows around the exterior surface of solvent interior tube 54 therein. When this flow of air encounters the restricted diameter of rear channel 60 in the venturi hose barb 58, the flow of air is compacted. Then, as the air flows through restricted rear channel 60 around interior tube 54 it has increased velocity which appears to reduce the pressure at the tip end 55 of interior tube 54 and venturi action occurs at the terminal tip end of interior tube 54. This increases the solvent flow from interior tube 54 and back through the entire solvent flow system to the solvent entering drop tube 22 in solvent tank 12. As the solvent exits from tip end 55 of interior tube 54, it becomes an atomized mixture with the compressed air within the forward channel 60 passing through flush nozzle 74. While this increased flow of solvent is occurring, the compressed air flowing through air bleed orifice 42 is maintaining only a gradual small increase in the air pressure in the tank. As the solvent is being forced up the drop tube in the tank with the increased velocity, a small reduction in air pressure occurs in the tank which hesitantly slows the flow of solvent up drop tube 22 until the air pressure in the tank immediately builds up again. This creates a continuous rise and fall of air pressure in the tank which in turn causes an intermittent flow of solvent leaving the tank. The continuous rise and fall of the air pressure causes a rapid pulsing action of the solvent as it exits interior tube 54 in restricted forward channel 60 in the hose barb 58. The atomized mixture of solvent and air passes through flush hose 20 attached by a quick disconnect coupler or similar means to fluid lines 62 in heat exchanger 24 from which it passes through and flushes out the fluid lines. It is this pulsing action of the atomized mixture of cleaning solvent and air through the fluid lines which dislodges and removes particles and debris from the fluid lines which contamination cannot be removed by just a constant flow of cleaning liquid through the fluid lines.
After passing through and flushing out fluid lines 62 of the heat exchanger, the solvent and air mixture enters return hose 26 attached to the outlet end of the heat exchanger.
With respect to the operation of the solvent recovery system of the invention, FIG. 1 shows drain hose 26 connected to the outlet end of the fluid lines of the heat exchanger. The drain hose is coupled through drain hose barb 64 to elbow 66 to atomized solvent defuser 30 mounted through cover 70 and into enclosed drain container 28. Activated charcoal filter 32 is also mounted through cover 70 into the drain container. The combination of the position of the angles of solvent defuser 30 and the slight build-up of air pressure in drain container 28 causes a swirling action in the solvent being collected in the bottom of drain container 28. The air flowing out of the drain container 28 passes through outlet elbow 76 and is filtered through activated charcoal filter 32 to eliminate odors and emissions of solvent vapors to the atmosphere.
A further embodiment of the invention is safety valve 72 shown in FIGS. 3 and 4. The safety valve threadedly engages the female threaded outlet of safety relief branch air passage 40 which intersects with main air chamber 34. The safety valve is structured to control the air pressure build-up in the manifold to be less than about 70 p.s.i. or as required for safe operation. The safety valve operates to relieve air from the main air chamber and also serves as a warning if the system becomes blocked or restricted.
The dimensions and size of manifold 10 and solvent tank 12 depend upon the size of the fluid lines to be cleaned. It is important that the size of bleed orifice 42 restricting the flow of compressed air into the solvent tank must function in combination with the restricted air space 61 formed between interior tube 54 and the restricted forward channel 60 to control the pulsing flow of solvent and the atomization of solvent in the air flow as discussed. The dimension and size of manifold 10 which have been found to meet the requirements of the invention are as follows. The manifold has a rectangular structure about three and three quarter inches in length, about two inches in width and about one inch in depth. Bleed orifice 42 is about three sixteenths of an inch in diameter. Drop tube 22 is about ten inches in length and an inside diameter of one quarter of an inch. Interior tube 54 is about two inches in length about one quarter of an inch of the length pressed into downstream solvent passage 46, about three quarters of an inch passes inside downstream air passage 36, and rear channel 56 and about one half of an inch passes inside forward channel 60 of the venturi hose barb, resulting in that about three quarters of an inch extends beyond the outside front edge of the manifold inside venturi hose barb 58. Venturi hose barb 58 is about one and three quarter inches in length having its forward channel 56 about one half inch in length with about one quarter inch of this threaded into the manifold and about one quarter inch extending beyond the outside front edge of the manifold, and having forward channel 60 about one and one quarter inches in length while interior hose 54 extends about one half inch into restricted diameter rear channel 60. The inside diameter of rear channel 56 is about one half of an inch, the inside diameter of restricted diameter forward channel 60 is about three eights of an inch, the outside diameter of interior tube 54 is about one quarter of an inch, and restricted air space 61 being about one eight of an inch opening. The inside diameter of main air chamber 34 is about seven sixteenths of an inch and that of downstream air chamber 36 and opening 37 is about five eights of an inch. The remaining air passages have about one quarter of an inch inside diameters.
Manifold 10 may be constructed of metal, plastic or rubber. Generally, copper tubing is preferred for drop pipe 22 and interior tube 54 although other materials are applicable. A frictionally releasable shut off valve 48 has been made of plastic which has been found to function well into an aluminium or steel manifold structure.
The manifold has been used efficiently with a solvent tank having a capacity of about six gallons which is about eleven inches in diameter and about fifteen inches in length.
The foregoing disclosure and description of the invention is illustrative and explanatory thereof, and various changes in the size, shape and materials as well as the details of the illustrated construction may be made within the scope of the appended claims without departing from the spirit of the invention. | The disclosure relates to an apparatus and method for cleaning fluid lines by use of an improved inline manifold. The manifold controls the flow of cleaning liquid causing a pulsing action of an atomized mixture of cleaning liquid and air through the fluid lines. The apparatus includes a hose for carrying cleaning fluid and air to the fluid lines, a source of compressed air, an enclosed tank containing cleaning liquid and the manifold operatively connected to the air source and the tank. | 5 |
STATEMENT OF INVENTION
This invention relates to tenter frames and more particularly to means between guide rail joints which provide a smooth path of travel for the tenter clips arranged in a chain.
BACKGROUND OF THE INVENTION
Tenter frames are commonly employed in web treating processes of the textile and thermoplastic film manufacturing industries.
Such frames consist of a multiple number of guide rails pivotally connected together. Each guide rail has opposite and parallel guide surfaces which provide a working surface and a return surface for an endlessly moving tenter clip chain.
Each tenter frame consists of two oppositely located guide rails. Two saddles, one for each guide rail, are slidably mounted upon a cross member of the machine frame. A shaft having a left hand thread and a right hand thread is rotatably mounted to the cross member. The two saddles are, respectively, connected to the left hand thread and the right hand thread. Rotation of the shaft moves the two saddles toward and away from each other to decrease or increase the distance between the two oppositely located saddles and guide rails. This movement causes adjacent guide rails to pivot around a connecting pivot pin and thereby increase or decrease the gap between adjacent guide rails.
The tenter clips pivotally connected together form a tenter chain. The clips ride against the working surfaces and return surfaces of the guide rails which form a guide path. The tenter clips located in the oppositely located guide rail paths grasp the edges of the webs being treated and convey these webs across the tenter frame.
Thermoplastic film is commonly stretched in the transverse direction by use of such tentering means. The tenter clips passing from one guide rail section to the pivotally connected adjacent guide rail section encounter a gap between adjacent guide rail sections. This gap causes the tenter clip to jar, jump and shockingly abut the opposite edges of the gap and in general hinder the smooth gentle passage of the tenter clips around the, respective, guide rail paths.
The jarring causes a ripple and thereby the destruction of a section of the thermoplastic film web. The jumping hinders the speed of movement of the tenter chain in the guide path. The shocking physically destroys both the guide path and the tenter clips and significantly increases the requirement of the driving motor. The gap also causes the tenter chain to vibrate. The result is nonuniformity of product, web breaks, and a major cause of equipment failure.
OBJECTS OF THE INVENTION
Accordingly, it is an object of the present invention to obviate the gap between guide rail sections.
Other objects of the present invention will be pointed out in part and become apparent in part in the following specification and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
Referring to the drawings in which similar characters of reference indicate corresponding parts in all the figures:
FIG. 1 is a schematic plan view of a tenter frame, showing the pivotally connected guide rail sections, the shafts with left hand and right hand threads and a few tenter clips which form a section of a tenter chain.
FIG. 2 is a right side elevational view of FIG. 1;
FIG. 3 is a diagrammatic view illustrating the relative position of the guide rail sections in parallel and divergent positions and showing the discontinuous boundaries or gaps between sections;
FIG. 4 is a fragmentary cross sectional view taken on line 4--4 of FIG. 1, showing the pivotal mechanism between adjacent guide rail sections;
FIG. 5 is a fragmentary cross sectional view, taken on line 5--5 of FIG. 1; showing one form of a guide rail; and one style of tenter clip.
FIG. 6 is a perspective view of another form of tenter clip adapted to ride in the track provided by the guide rail section shown in FIG. 5;
FIG. 7 is a perspective view of still another form of tenter clip;
FIG. 8 is a vertical cross-sectional view showing the tenter clip of FIG. 7 riding in a guide rail having a modified form when compared to the guide rail shown in FIG. 5;
FIG. 9 is a fragmentary perspective view of the guide rail section (shown in FIG. 5) pivotally attached to a saddle which is slidably mounted upon a cross member;
FIG. 10 is an enlarged view, partly in cross-section, of pivotally connected adjacent guide rail sections, showing the gap between the ends of guide rail sections, and one form of the present invention which obviates the gap for the traveling tenter clips;
FIG. 11 is a view, similar to FIG. 10, showing a modified form of gap crossing mechanism in position between adjacent guide rail sections;
FIG. 12 is a perspective view of the modified form of gap crossing mechanism, per se, shown in FIG. 11;
FIG. 13 is a fragmentary vertical cross sectional view taken on line 13--13 of FIG. 1 with the adjacent section omitted;
FIG. 14 is a vertical cross sectional view similar to FIG. 5 showing a modified form of guide rail construction;
FIG. 15 is a fragmentary plan view of pivotally connected adjacent guide rail sections illustrating another modified form of gap crossing mechanism mounted upon the guide rail shown in FIG. 14;
FIG. 16 is a fragmentary vertical cross sectional view taken on line 16--16 of FIG. 15;
FIG. 17 is a view similar to FIG. 16 taken on line 17--17 of FIG. 15;
FIG. 18 is a fragmentary cross sectional view, taken on line 18--18 of FIG. 15;
FIG. 19 is a fragmentary vertical cross sectional view, similar to FIG. 18, taken on line 19--19 of FIG. 15; and
FIG. 20 is a diagrammatic view illustrating the maximum divergence angle between adjacent pivotally connected guide rail sections in accordance with the modified form shown in FIGS. 15 through 19.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In proceeding with this invention, reference is made to the drawings, wherein is illustrated the new and improved tenter frame gap crossing mechanism.
The tenter frame comprises major structural sections, all generally indicated as follows: A plurality of stands 10 in FIG. 2, a frame 11 in FIGS. 1 and 2, with cross members 12 in FIGS. 1, 4 and 9, a plurality of saddles 13 in FIGS. 2, 4 and 9, a plurality of shafts 14 in FIGS. 1, 2, 4 and 9, and a plurality of pivotally connected guide rail sections 15 in FIGS. 1, 2, 3, 4, 5, 8, 9, 10, 11, 13, 14, 15, 18, 19 and 20.
Stands 10 consist of a unitary structure 16 having a base 17 and top surface 18 (see FIG. 2), to be used in a plurality of units in a horizontal line, and in a plurality of units in a longitudinal line, oppositely disposed unit for unit with the first horizontal line.
The frame 11 consists of a left side 20 and a right side 21 fastened, respectively, to the stands 10 arranged in the, respective, longitudinal line. Cross members 12 are fastened on opposite ends to left side 20, and right side 21. Cross members 12 are provided with a horizontal top sliding surface 23 and two opposite and parallel sliding surfaces 24 and 25. (see FIG. 9). A plurality of left side bearings 26 are fastened to left side 20. A plurality of right side bearings 27 are fastened to right side 21 and are located opposite and parallel to bearings 26, respectively. A plurality of center bearings 28 are fastened to the, respective, cross members 12 in alignment with the, respective, left side 26 and right side 27 bearings.
A plurality of shafts 14, each provided with a left hand thread 31 and a right hand thread 32 are rotatably mounted on opposite ends in the, respective, left side bearings 26, right side bearings 27 and centrally in center bearings 28.
A plurality of hand wheels 33 are provided, with one hand wheel fastened to one end of each shaft 14.
A plurality of saddles 13, two for each cross member 12, are provided with a body 40 having sliding faces 41 and sliding ends 42, 43, to slidingly engage, respectively, top sliding surface 23 and opposite and parallel sliding surfaces 24, 25.
With reference to FIG. 13, saddle body 40 is provided with a plurality of inverted "U" shaped projections 50, 51, 52, 53, 54 and 55 which form chambers 56, 57, 58, 59 and 60. Inverted "U" shaped projections 50, 51, 52, 53, 54, 55 straddle shaft 14 to allow shaft 14 to freely rotate. A nut 61 provided with a screw thread of a hand adapted to rotatively engage left hand thread 31 or right hand thread 32, is located in chamber 56 and is held therein by means of inverted "U" shaped projections 50, 51.
Rotation of hand wheel 33 causes nut 61 to engage either inverted "U" shaped projection 50 or 51 to slide saddle 13 upon cross member 12 toward or away from center bearing 28.
With reference to FIGS. 9 and 13, saddle body 40 is provided with a longitudinal groove 62. A block 63 is slidably mounted in longitudinal groove 62. A pivot pin 64 is fastened in block 63.
The plurality of pivotally connected, grooved guide straight rail sections 15, are each provided with two tenter clip tracks, vis, a working side track 66 and a return side track 67. Each rail section 15 has a pivotal recess 68 on one end and a pivotal tongue 70 on the opposite end. (see FIGS. 1, 9 and 10.) Pivotal tongues 70 are adapted to pivotally engage pivot pins 64 and lie in the, respective, pivotal recess 68. In this manner a plurality of pivotally connected straight or longitudinally grooved guide rail sections 15 provide a left side guide path, generally indicated at 72, (in FIG. 1) for tenter clips formed into a closed loop circulating tenter chain and a similar right side guide path, generally indicated at 73.
The diagrammatic view, FIG. 3, shows that the guide rail sections 15, while constituting straight sections, may constitute straight sections of varying lengths so that in pivoted relationship, gaps 5 of varying widths exist between adjacent guide rail sections 15. As will presently appear, the shafts 14 and saddles 13 adjust the guide rail sections 15 in divergent and convergent relationship to provide curved paths for the tenter clip chains.
The two guide paths 72, 73 provide an infinite variety of curves which are equal but opposite for processing web material gripped on opposite sides by the tenter clips of the, respective, tenter chains.
The tenter frame is provided with two driving sprockets 120, 121 (see FIG. 1), driven by motors 122, 123 by means of shafts 124, 125, respectively, and two driven sprockets 126, 127. Tentering chain 111 is operatively connected to sprockets 121, 127. Tentering chain 110 is operatively connected to sprockets 120, 126. Tentering chains 110, 111 are driven in the direction of arrows "A" and "B".
In operation, the movement of tenter chains 110, 111 in guide paths 72, 73, respectively, carry a web to be stretched from the pick up end or web receiving region of the tenter frame between sprockets 126, 127 to the delivery end or web discharge region of the tenter frame between sprockets 120, 121. Suitable cams 120A, 121A engage upstanding arms 130 of the pivot jaws 90 causing lower edges 91 to swing away from base 81 and disengage the web (not shown). At the web receiving region cams 126A, 127A engage arms 130 to pivot jaws 90 away from base 81. As arms 130 of the tenter clips of chains 110, 111 move in the direction of arrows A and B, the arms 130 disengage cams 126A, 127A to release pivoted jaws 90 to the action of gravity to grip the web between bases 81 and lower edges 91. Pin 198 pivotally connects jaw 90 to tenter clip body 300.
Rotation of hand wheels 33 cause the, respective, saddles 13 to slide upon cross members 12, whereby, the guide rail sections 15 and the tenter clip tracks 66, 67 thereby provided, are moved in relation one to the other to provide a preselected path of movement for the respective tenter clip chains 110, 111. That preselected path is under very close tolerance adjustment due to threads 31, 32 on shafts 14. FIGS. 1, 2, 3, 10 and 11 clearly illustrate the gap 5 or space between adjacent divergent guide rail sections 15. The gap 5 must permit the tenter clip to pass from one guide rail section to the adjacent divergent guide rail section, smoothly and without the slightest jar or vibration or the plastic film in a heat softened condition will have imparted to it, a wrinkle, a ridge or a tear.
One form of guide rail section 15 construction is shown in FIGS. 5, 9 and 10 wherein the guide rail section comprises a tenter clip working side 225, a tenter clip return side 226 connected together on opposite ends by a front rib 227 and a rear rib 228. Working side 225 is provided with a working side depending arm 230 having a first supporting face 131 and a depending first rib 132. Return side 226 is provided with a return side depending arm 133 having a second supporting face 134 and a depending second rib 135. Working side 225 is provided with a working side track 66 comprising a front flange 136 having an upper forward tenter clip engaging face 137, a rear flange 229 having a lower rear tenter clip engaging face 138 and a base 139, which combine to form a "U" shaped grooved track 66. Similarly, body 226 is provided with a return side track 67 comprising a front flange 140 having an upper forward tenter clip engaging face 141, a rear flange 145 having a lower rear tenter clip engaging face 142 and a base 143, which combine to form a " U" shaped grooved track 67.
Front flange 136 is provided on opposite ends with chambers 144, 144A having, respectively, a window in upper forward working face 137. Similarly, front flange 140 is provided on opposite ends with chambers 147, 147A having, respectively, a window in upper forward working face 141.
Rear flange 229 is provided on opposite ends with chambers 146, 146A having, respectively, a window in lower rear working face 138. Similarly, rear flange 145 is provided on opposite ends with chambers 148 having, respectively, windows in lower rear working face 142.
Reference is made to FIGS. 5 and 10, wherein a coil spring 150 having a flat tenter clip engaging surface "S" is located on opposite ends in a rear chamber 144 and a front chamber 144A provided in opposite ends of pivotally connected adjacent guide rail sections 15. A first dowel pin 160, shorter in length than rear chamber 144 is inserted into one end of coil spring 150. A tapered ended dowel pin having a medial area 161 is inserted into the medial area of coil spring 150. A second dowel pin 162 shorter in length than front chamber 144A is inserted into the other end of coil spring 150. A first space 163 is provided between the end of first dowel pin 160 and one end of tapered ended dowel pin 161. A second space 164 is provided between the end of second dowel pin 162 and the other end of tapered ended dowel pin 161. A first set screw 165 rotatably fastened in rail 15 secures one end of coil spring 150 in rear chamber 144 by forcing the coils against dowel pin 160. A second set screw 166 rotatably fastened in rail 15 secures the opposite end of coil spring 150 in front chamber 144A by forcing the coils against dowel pin 162.
The medial area 161 reinforces coil spring 150 at the gap to support the spring when a tenter clip rides across flat tenter clip engaging surface "S".
In like manner a coil spring 150A is located in rear and front chambers 146, 146A respectively, provided in opposite ends of pivotally connected adjacent guide rail sections 15. With first dowel pin 160A and second dowel pin 162A inserted, respectively, in opposite ends of coil spring 150A. A tapered ended dowel pin 161A is inserted into the medial area of coil spring 150A. First set screw 165A and second set screw 166A, rotatably fastened in adjacent rails 15, secure one end of coil spring 150A in rear chamber 146 at the dowel pin 160A and the other end of spring 150A in front chamber 146A at the dowel pin 162A.
The tenter clip shown in FIGS. 5 and 6 is provided with an upper roller 170 and a lower roller 171, both rollers are rotatively mounted to a shaft 302 held in tenter clip body 300. Reference is made to FIGS. 5 and 10, as rollers 170, 171 ride against working faces 141, 142, respectively, they encounter the gap 5 now closed by coil springs 150, 150A as a continuation of working faces 141, 142, respectively. In this manner, the rollers 170, 171 smoothly pass from one rail 15 to the adjacent rail 15 without jar.
The coil springs 150, 150A fastened in the respective chambers, expand and contract with the opening and closing of gap 5.
The rails 15 are provided with ledges 367, which are complimentary tapered on opposite ends, as at 368, so as to engage with a clearance therebetween when the rails are in alignment.
The style of tenter clip shown in FIG. 5 is provided with a front roller 69. Roller 69 may pass from one ledge 367 to the adjacent ledge 367 without jar due to the complimentary taper of the ends of adjacent rail sections 15, whether the gap 5 is minimal or maximal. There is always a gap between adjacent rail sections 15 to accommodate expansion and contraction of the rail sections 15 when subjected to a heating oven environment.
FIGS. 11 and 12 illustrate a modified form of crossing gap mechanism. Whatever means are used to close the gap 5 between adjacent rail sections, that means must yield to the arcuate relative movement between the ends of adjacent straight guide rail sections.
A bar, generally indicated at 180 comprises two compatible half sections 185, 185A which slidably engage. One face 181 of bar 180 is made flat to provide a tenter clip engaging face. Three (more or less) slits 182 are made in the surface opposite said tenter clip track surface so that bar 180 will bend or yield in an arcuate direction, thereby arcuately shaping flat face 181. The bar 180 is then separated into two opposite but identical half sections, upper 185 and lower 185A, so that each half section has a sliding surface 183, a head 186 and a shoulder 184 formed in the head at the juncture of the sliding surface 183. In this construction, the upper section 185 may slide relative to lower section 185A, when as shown in FIG. 11 the half sections are fastened in chambers 144, 144A by means of set screws 165A and 166A. The slits 182 permit the two sections 185, 185A to yield when the rail sections 15 pivot around pin 64 causing the sections 185, 185A to arcuately bend relative to pivot pin 64 which is the center of the radius of the arc.
Bar 180 functions in the same manner as coil spring 150 in relation to adjacent rail sections 15 and the accommodated tenter clips.
FIGS. 7 and 8 depict a modified form of tenter clip and tenter rail. This form is generally used on material woven from cotton, wool and/or synthetic fibers. The rail and tenter clips shown in FIG. 5 are the form generally used on thermoplastic web material.
Both forms use tenter clips, formed in a pair of closed loops, which travel in a pair of sectionalized grooved guide rail sections arranged in closed loop paths, spaced in parallel relation to provide a uniform distribution of transverse stretching forces.
The tenter clip, generally indicated by reference numeral 190 (see FIGS. 7 and 8) is provided with a horizontal body 191 having a plate 192 and a projection 193 providing a tenter clip engaging face 194. A pair of arms 195, 196 integrally connected to said body 191 overlie plate 192. A pivotal jaw 90 pivotally connected to arms 195, 196 through pin 198, pivotally engages plate 192 through the force of gravity.
The guide rail section, generally indicated at 15A comprises a body having a groove 200, a tenter clip engaging face 201 and a base 202. The tenter clip 190 is slidably mounted in groove 200, with tenter clip engaging face 194 slidably engaging tenter clip engaging face 201 while being supported upon base 202. A top case 203 is fastened to guide rail section 15A, by means of screws 204, which overlies horizontal body 191 so as to retain tenter clip 190 in groove 200. The tenter clips 190 are pivotally connected into a closed loop as shown in FIG. 1 and operationally described for the specie tenter clip shown in FIG. 5.
Chamber 247 is provided in body 199 and coil spring 150 or bar 180 may be housed therein as previously described in relation to FIGS. 5, 9, 10, 11 and 12.
FIG. 14 depicts a modified form of pivotally connected grooved guide rail section. The structure described in relation to FIG. 5 applies to FIG. 14 with one modification. The reference numerals of FIG. 5 and the description which applies to FIG. 14 have an "A" applied when used on FIG. 14.
Guide rail section 15A having a body 226A is provided with a return side track 67A in the form of a groove formed by a front projection 251, a rear flange 145A and a base 143A. A front projection wear strip 140A having an upper forward tenter clip engaging face 141A is fastened to front projection 251 as by means of screws 253. Rear flange 145 is cut back to provide a seat 252 and a longitudinal surface 254. A rear wear strip comprises a body 255 having an upstanding arm 256 and a lower tenter clip engaging face 142A, is slidably mounted upon seat 252. A plurality of clearance orifices 257 are provided in upstanding arm 256. A plurality of machine screws 258 pass through clearance orifices 257 and are rotatably supported in rear flange 145A. A split washer 259 may be interposed between the head of screw 258 and arm 256. A spring or a compression washer 260 is supported upon screw 258 and interposed between upstanding arm 256 and rear flange 145A to yieldingly urge tenter clip engaging face 142A toward tenter clip engaging face 141A. In this manner, tenter clip rollers 170A and 171A, engaging tenter clip engaging faces 141A and 142A, respectively, are yieldingly held in return side track 67A or in the working side track (not shown because the structure is a duplication of track 67A).
Front flange wear strip 140A being a part of the pivotally connected grooved guide rail section 15A is provided on opposite ends with chambers 147 and 147A as described in structure and purpose with reference to FIGS. 5, 10, 11 and 12.
Similarly, wear strip body 255 being a part of the same pivotally connected grooved guide rail section 15A is provided on opposite ends with chambers 148, 148A as described in structure and purpose with reference to FIGS. 5, 10, 11 and 12.
Reference is now made to FIGS. 15, 16, 17, 18 and 19 wherein is depicted a modified form of gap crossing mechanism as applied to the pivotally connected grooved guide rail sections described in relation to FIG. 14. The structural features in FIG. 19 corresponding to the identical structural features described with reference to FIG. 14 will have a suffix "C" added to the reference numerals.
The form of pivotally connected grooved guide rail sections 15C shown in FIGS. 15 through 19, comprise a body 226C having a return side track 67C in the form of a groove formed by a front projection 251C, a rear flange 145C and a base 143C. Body 226C terminates on opposite ends in an edge E. (see FIG. 15).
The tenter clip working side of rail section 15C is identified as 66C and the tenter clip return side is identified as 67C which are connected together on opposite ends by a front rib 227C and a rear rib 228C. As previously described, each rail section 15C has a pivotal recess 68C on one end and a pivotal tongue 70C on the opposite end (see FIG. 15). Pivotal tongues 70C are adapted to pivotally engage pivot pins 64C and lie in the, respective, pivotal recesses.
Each guide rail section 15C is provided with a plurality of front projection wear strips 140C, having an upper tenter clip engaging face 141C. Each wear strip 140C is fastened to front projection 251C as by means of screws 253C. The rear flange 145C is cut-back to provide a seat 252C and a longitudinal surface 254C. A rear wear strip comprises a body 255C having an upstanding arm 256C and a lower tenter clip engaging face 142C, is slidably mounted upon seat 252C. A plurality of clearance orifices 257C are provided in upstanding arms 256C. A plurality of machine screws 258C pass through clearance orifices 257C and are rotatably supported in rear flange 145C. A split washer 259C may be interposed between the head of screw 258C and arm 256C. A spring or a compression washer 260C is supported upon screw 258C and interposed between upstanding arm 256C and rear flange 145C to yieldingly urge tenter clip engaging face 142C toward tenter clip engaging face 141C. Each wear strip body 255C is provided with a plurality of enlarged bolt holes 303. A plurality of bolts 304, one for each bolt hole 303 passes through the, respective, bolt hole 303 and is rotatably mounted in body 226C so that wear strip 255C is able to move laterally and longitudinally. In this manner, tenter clip rollers 170C and 171C, engaging tenter clip engaging faces 141C and 142C, respectively, are yieldingly held in return side track 67C or in the working side track 66C. (see FIG. 15).
Each section "L" (see FIG. 15, 16, 17) of the plurality of front projection wear strips 140C and the rear wear strip body 255C are provided with a lower cut-away or lower shelf on one end 275 and an upper cut-away or upper shelf 276 on the opposite end. In this manner, the upper shelf 276 is slidably mounted upon the lower shelf 275 of the adjacent wear strip for thermal expansion and contraction and pivotal movement.
The last section "L" of the plurality of front projection wear strips 140C and the last section of rear wear strip body 255C are made round (as seen in FIG. 15).
The last section "L--L" of the plurality of front projection wear strips 140C and the last section "L--L" of rear wear strip body 255C are provided with elongated slots 280.
Shoulder bolts 306 pass through elongated slots 280 and are fastened in body 226C.
The upstanding arms 256C attached to sections "L--L" are provided with elongated slots 307 to permit sections "L--L" to move relative to machine screws 258C.
Pivotal movement of guide rail sections 15C relative to each other causes sections "L--L" pivotally connected to an adjacent section "L" on one end, to move laterally relative to the section "L" on the opposite end.
As previously described, hand wheels 33 cause the saddles 13 to slide upon cross members 12, whereby the grooved guide straight rail sections 15C are moved in relation one to the other and thereby, pivot on pivot pins 64C to cause a divergence or convergence of the ends E of adjacent guide rail sections to increase or decrease the gap between adjacent rail sections 15C.
As will be noted in FIGS. 15, 16 and 17 wear strip body 255C provided with the elongated slots 280 will slide in relation to the adjacent guide rail sections on opposite ends and will pivot around pivot pin 364C, thereby to provide a smooth arcuate guide rail gap crossing mechanism.
FIG. 20 is a diagrammatic view illustrating a roller 170C or 171C riding against the tenter clip engaging face of pivotally connected adjacent grooved guide straight rail sections 15C. Empirically, it is believed that the angle between pivotally connected guide rail sections 15 will approximate two and one-half degrees. This numerical value is an observation and not a limitation.
FIG. 18 illustrates the rollers 170C and 171C engaging the guide rail gap crossing mechanism shown in FIGS. 15, 16, 17 and 19.
Having shown and described preferred embodiments of the present invention, by way of example, it should be realized that structural changes could be made and other examples given without departing from either the spirit or scope of this invention. | This invention relates to tenter frames and more particularly to a tenter rail provided with a gap crossing mechanism whereby the tenter clip engaging surfaces of the tenter guide rails, at the rail joints, are smooth for the gentle passage of the tenter clips arranged in a chain. | 3 |
This is a continuation of application Ser. No. 867,483, filed May 27, 1986, now abandoned.
BACKGROUND OF THE INVENTION
This invention relates generally to flexible door structures and is particularly directed to lightweight, pliable roll-type overhead doors.
Roll-type doors are frequently used in industrial installations to isolate two rooms or the inside of a building from the outside environment while permitting transit between the two rooms or either out of or into the building as desired. These roll-type doors are generally mounted on a pair of vertically aligned tracks and are securely coupled at an upper end portion thereof to a roller which is rotated in a first direction to lower the door or in a second direction to retract the door. The roller is typically mounted immediately above the doorway and generally includes an electric motor for rotationally displacing the roller. Doors of this type have generally been comprised of a plurality of rigid hingedly interconnected metal panels which can be wrapped around the roller when retracted for storage while providing a rigid door structure of high strength when lowered in position in the doorway.
Recent developments in the area of roll-type doors have given rise to another type of door comprised of a pliable sheet-like structure which frequently is transparent and is adapted for rapid displacement between the retracted, rolled up configuration and the lowered, extended configuration. These doors are typically comprised of a high strength plastic material such as polyvinyl chloride only limited success in maintaining the door in a laterally stretched condition so that it remains extended from one side of the doorway to the other. The absence of lateral rigidifying means in existing pliable, lightweight roll-type doors has limited their usefulness in environments where wind is a factor or where a large pressure differential exists between the two rooms separated by the door.
Some prior art doors of this type incorporate trolleys coupled to respective lateral-edge portions of the pliable door which are mounted in and displaceable within respective tracks positioned adjacent to lateral portions of the door. While this trolley/track arrangement maintains the pliable door laterally taut, such arrangements substantially increase the complexity and cost of the door installation.
The present invention overcomes the limitations of the prior art by providing structural means for maintaining a lightweight, pliable, roll-type door in a laterally stretched condition across a doorway without the use of a trolley/track combination. The present invention contemplates one or more windstraps positioned in spaced relation along the length of the door and extending substantially the width thereof so as to maintain the door generally flat even when subjected to lateral loading on one surface thereof such as due to wind or a pressure differential. (PVC) and may be displaced from the open to the closed position, or vice versa, in just a few seconds. As this type of door lacks the structural strength of the aforementioned multi-section hinged roll-type door, roll-type doors comprised of a single pliable sheet-like member are intended primarily for environmentally isolating two adjacent rooms or the inside of a building from the environment outside rather than for providing security by preventing transit through a doorway. A rapidly displaced overhead roll-type door having good insulating characteristics is particularly desirable from an energy conservation standpoint where there is a large differential between inside and outside temperatures.
A primary difference between the single sheet, pliable roll-type doors and the aforementioned multi-section, hingedly interconnected rigid roll-type doors is that the former require tensioning means coupled to the lower end portion of the door in order to maintain the door in a taut condition so as to prevent lateral displacement of the door, while in the latter installation the considerable weight of the door maintains the door in a planar configuration during raising and lowering. Pliable roll-type door tensioning arrangements typically include various combinations of springs, pulleys and weights to exert a downward force on the lower edge portion of the door so as to maintain it generally planar across the doorway when it is extended. Thus, while the prior art has provided for stretching pliable overhead roll-type doors in a generally vertical direction to maintain the door in a flat configuration, prior art approaches have met with
OBJECTS AND SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide an improved lightweight, pliable, roll-type overhead door.
It is another object of the present invention to provide reinforcement for an overhead roll-type door which is lightweight, allows the door to be tightly rolled up, and permits the door to remain in position across a doorway even under high wind loads.
Yet another object of the present invention is to provide a windstrap for a pliable roll-type overhead door which is lightweight, easily installed, can be retrofit on existing doors, and does not interfere with the rapid rolling up and unrolling of the door.
The present invention contemplates a windstrap for a pliable roll-type overhead door which permits the door to withstand wind and other forms of loading while remaining in position across an opening in isolating the areas on each side of the door. The windstrap includes a pair of metal straps mounted to respective opposing surfaces of the door and mutually coupled by a plurality of spaced rivets inserted therethrough. Positioned along the length of each strap is a respective anti-friction pad for protecting the door, which typically is comprised of a transparent plastic, from damage and wear by the mounting rivets during the retraction/extension of the door. More than one windstrap may be positioned on the door to accommodate increased door loading, with the windstraps positioned on the door so as to be generally equally spaced along the length of the door when extended and equally spaced around the roller from a pressure strap coupling the upper end of the door to the roller when the door is rolled up.
BRIEF DESCRIPTION OF THE DRAWINGS
The appended claims set forth those novel features which characterize the invention. However, the invention itself, as well as further objects and advantages thereof, will best be understood by reference to the following detailed description of a preferred embodiment taken in conjunction with the accompanying drawings, where like reference characters identify like elements throughout the various figures, in which:
FIG. 1 is a front plan view of a roll-type overhead door having a windstrap thereon in accordance with the present invention;
FIG 2 is a lateral view of a roll-type overhead door assembly of FIG. 1 taken along sight line 2--2 therein;
FIG. 3 is a partial perspective view of a windstrap installation for a pliable roll-type overhead door in accordance with the present invention;
FIG. 4 is an exploded perspective view of a windstrap for a pliable roll-type overhead door of the present invention showing the installation thereof on the door;
FIGS. 5 and 6 are lateral sectional views of rollers on which are rolled a pliable door in an overhead door installation wherein the doors respectively include one and two windstraps positioned thereon.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIGS. 1 and 2, there are respectively shown front and lateral views of a roll-type overhead door assembly 10 in which the windstrap 50 of the present invention is intended for use.
The roll-type overhead door assembly 10 is adapted for secure mounting to a wall 42 about an aperture, or doorway, 42a therein. The overhead door assembly 10 includes left and right housings 12, 14 which are generally vertically oriented and are positioned upon a support surface, or floor, 16 immediately adjacent to respective lateral portions of the doorway 42a within the wall 42. Securely mounted to respective upper end portions of the left and right housings 12, 14 are left and right mounting brackets 18, 19. Positioned between and supported by the left and right mounting brackets 18, 19 is a door roller 26 which is freely rotatable within the mounting brackets. Positioned immediately adjacent to the right mounting bracket 19 on the upper end portion of the right housing 14 is the combination of a gear box 20 and an electric motor 22. The gear box 20 includes a drive sprocket 24 coupled thereto which, in turn, is coupled by means of a drive belt 25 to a roller sprocket 27 mounted on one end of the door roller 26. Actuation of the electric motor 22 results in rotational displacement of the drive sprocket 24 via the gear box 20 causing the rotational displacement of the combination of the roller sprocket 27 and the door roller 26. With a rolling door, or curtain, 28 mounted to and supported by the door roller 26, rotation of the door roller in a first direction results in a lowering of the door to an extended, closed position, while rotation of the door roller in a second direction results in a raising of the door to a retracted, stored position.
Positioned on respective ends of the door roller 26 immediately adjacent to the left and right mounting brackets 18, 19 is a take-up pulley 21. For simplicity, only the left take-up pulley 21 is shown in FIG. 1. A reinforced belting, or cable, 32 is attached to and disposed around each of the take-up pulleys 21. Each of the cables 32 is suspended downward from an associated take-up pulley 21 and is routed via a respective pulley 36 within an associated lateral housing to permit a second end 32a of each of the cables to be securely coupled to respective lateral portions of a bottom rail 30 of the rolling door 28. The bottom rail 30 is securely coupled to and integral with the lower end portion of the rolling door 28.
The overhead door assembly 10 further includes a door tension/counterbalancing mechanism 44 which may be coupled to one or both of the left and right cables 32. The door tension/counterbalancing mechanism 44 may be conventional in design and operation and typically includes various combinations of springs, pulleys, and weights designed to exert a downward, pulling force on the bottom rail 30 of the rolling door 28 in order to maintain the door in a stretched, flat configuration when positioned across the doorway 42a within the wall 42. Because the particular arrangement employed for exerting tension or a counterbalancing force upon the rolling door to maintain it in a vertically stretched condition does not form a part of the present invention, further details thereof are not provided herein. For simplicity, the door tension/counterbalancing mechanism 44 is merely shown as a block in FIG. 2 and may be coupled to either an upper mounting bracket 46 or a lower mounting bracket 48 within the right housing 14, or may be coupled to both mounting brackets. A similar arrangement may be provided in the left housing 12 for exerting a downward force on the lower left edge portion of the rolling door 28. Each of the left and right housings 12, 14 may be provided with the combination of a movable front panel and a plurality of hinges 40 to provide access to the cable and pulley or weight arrangement within the housing. Finally, a weather seal 34 is typically provided in an upper portion of the overhead door assembly 10 to maintain sealed engagement between the door assembly and the wall 42 immediately adjacent to the aperture 42a within the wall.
As shown in FIG. 1, a generally horizontally oriented windstrap 50 is positioned upon the rolling door 28 and extends substantially the width thereof. Similarly, exploded perspective views of a windstrap 50 for use with a roll-type overhead door 28 in accordance with the present invention are shown in FIGS. 3 and 4. The windstrap 50 includes a pair of elongated, linear straps 52 preferably comprised of stainless steel positioned on respective, opposing surfaces of the rolling door 28. The straps 52 are coupled and maintained in position by means of a plurality of coupling pins such as rivets 56 inserted in paired apertures in each of the straps along the lengths thereof. The rolling door 28 is also provided with a linear array of apertures therein positioned between the spaced straps 52 for allowing the insertion of the rivets therethrough. Positioned over each of the outer surfaces of the straps 52 is a respective anti-friction pad 54 which protects the rolling door 28 from abrasion and tearing when the door engages the windstrap 50 when in the rolled-up configuration. In a preferred embodiment, each of the anti-friction pads is comprised of a self-adhering loop of Velcro material positioned on a respective strap 52 along the length thereof. Similarly, in a preferred embodiment, the rolling door 28 is comprised of a transparent polyvinyl chloride (PVC) material which affords both strength and flexibility.
Referring to FIGS. 5 and 6, there are respectively shown sectional views of a door roller 26 around which is wound a rolling door 28. One end of the flexible door 28 is coupled to the outer, cylindrical surface of the door roller 26 by means of a pressure strap 62 positioned along the width of the rolling door and the length of the door roller. As shown in FIG. 5, the rolling door 28 is provided with a single windstrap 50. In this case, the windstrap 50 is located approximately midway between the bottom edge of the door and the door roller when fully extended and is positioned approximately 180° from a pressure strap 62 on the roller 26 when the door is rolled up. The pressure strap 62 securely couples the upper edge of the rolling door 28 along the width thereof to the door roller 26. The procedure for positioning of the pressure strap 62 is to initially mark the rolling door 28 with a line approximately one-half the height of the door when in the fully extended position. The rolling door 28 is then retracted upon the door roller 26 until the aforementioned marked line is positioned upon the roller, whereupon the line is then adjusted so as to be spaced approximately 180° from the position of the pressure strap 62 on the door roller 26.
As shown for the case of two windstraps 58, 60 positioned upon the rolling door 28 in FIG. 6, the rolling door is initially divided approximately into thirds and horizontal lines are marked thereon to show the approximate location of the equally spaced windstraps. The rolling door 28 is then retracted and wound around the door roller 26 until the aforementioned marked lines are positioned on the door roller. The two marked lines are then adjusted so as to be displaced approximately 120° in opposite directions from the pressure strap 62 on the door roller 26. Once the aforementioned lines are appropriately marked on the rolling door 28, the door is extended to the full open position and the windstrap (or windstraps) or windstraps are riveted to the rolling door as described above. By maintaining maximum angular displacement between the pressure strap 62 and the windstrap (or windstraps), overlapping of the windstrap and the pressure strap is prevented and the possibility of damage to the rolling door arising therefrom is eliminated. This also ensures that the rolling door is wound tightly on the door roller for maintaining the door in a taut configuration and ensuring that the rolling door is displaced upward and downward in a smooth, continuous manner.
There has thus been shown a pliable roll-type overhead door having a windstrap (or windstraps) positioned substantially along the width thereof for maintaining the door in a laterally stretched, taut configuration during the rolling up and unrolling of the door as well as when the door is in the extended position. The windstrap ensures that the pliable door remains in position over an aperture in a wall even when a pressure differential is applied across the door or when wind loading is imposed upon the door.
While particular embodiments of the present invention have been shown and described, it will be obvious to those skilled in the art that changes and modifications may be made without departing from the invention in its broader aspects. Therefore, the aim in the appended claims is to cover all such changes and modifications as fall within the true spirit and scope of the invention. The matter set forth in the foregoing description and accompanying drawings is offered by way of illustration only and not as a limitation. The actual scope of the invention is intended to be defined in the following claims when viewed in their proper perspective based on the prior art. | A windstrap secured to a lightweight, pliable, roll-type overhead door across the width thereof reinforces the door structure maintaining it in position across a doorway when the door is in the lowered, extended position and isolating the two areas on respective sides of the door when there is a pressure differential therebetween such as due to wind. | 4 |
STATEMENT OF PRIORITY AND RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional Application 60/741,494 filed on Nov. 30, 2005, entitled An Improved Electronic Colon Cleansing Method for Detection of Colonic Polyps by Virtual Colonoscopy, the disclosure of which is hereby incorporated by reference in its entirety.
STATEMENT OF GOVERNMENT RIGHTS
[0002] This work has been supported in part by National Institutes of Health Grant CA082402 of the National Cancer Institute. The United States government may have certain rights to the invention described and claimed herein.
BACKGROUND OF THE INVENTION
[0003] Colorectal cancer is a leading cause of cancer-related deaths in the United States. More than 90% of colon cancers develop from adenomatous polyps, removal of which can dramatically reduce the risk of death. Accepted guidelines recommend the screening of adults who are at average risk for colorectal cancer, since the detection and removal of adenomas has been shown to reduce the incidence of cancer and cancer-related mortality. Currently available detection methods include fecal occult blood tests, sigmoidoscopy, barium enemas, and fiber optic colonoscopies (OC). Unfortunately, most people do not follow this advice because of the discomfort and inconvenience of the traditional optical colonoscopy. To encourage people to participate in screening programs, virtual colonoscopy (VC), also known as computed tomographic colonography (CTC), has been proposed and developed to detect colorectal neoplasms by using a computed tomography (CT) or magnetic resonance imaging (MRI) scan. VC is minimally invasive and does not require sedation or the insertion of a colonoscope. Compared to OC, VC has the potential to become a common screening method in terms of safety, cost, and patient compliance. VC exploits computers to reconstruct a 3D model of the CT scans taken of the patient's abdomen, and creates a virtual fly-through of the colon to help radiologists navigate the model and create an accurate, efficient diagnosis. Previously known systems and methods for performing virtual colonoscopy are described, for example, in U.S. Pat. Nos. 5,971,767, 6,331,116 and 6,514,082, the disclosures of which are incorporated by reference in their entireties.
[0004] It has been demonstrated that the performance of VC can compare favorably with that of traditional OC. As is required with traditional optical colonoscopies, the colon needs a thorough cleansing before the VC and computer aided detection (CAD) of polyps. However, even with a rigorous cleansing of the colon, remaining stool and fluid residues may mimic polyps, thereby dramatically reducing the efficiency of the VC and CAD.
[0005] Electronic colon cleansing (ECC) may be used to improve the efficiency of VC and CAD by effectively removing colonic material from the acquired images. Preparing the colon for ECC varies slightly from traditional VC and CAD without ECC. A preliminary step of ECC is tagging the colonic material with a contrast agent. With the addition of a contrast agent, the tagged stool and fluid have an enhanced image density compared to the density of the colon/polyp tissues. By segmenting the colon images and recognizing patterns, ECC methods can be used to identify the enhanced colonic material and produce a “clean” colon model for both VC navigation and CAD analysis. A known ECC approach is to apply simple thresholds to the image data for segmentation and then removing certain tagged material. However, the effectiveness of the threshold approach to ECC may be impaired by a partial volume (PV) effect at various boundary regions, such as the air-colonic material interface and the colon/polyp tissue-colonic material interface.
[0006] Various approaches to mitigate the PV effect have been explored in the art. For example, a ray-based detection technique exists, which utilizes a predefined profiled pattern to detect interfaces. Other techniques use morphological and linear filters, image gradient information, and a priori models to mitigate the PV effect. Each of the previous methods relies on the assumption that limited information may be derived from an image voxel, which limits the effectiveness of the solution. As a result, improved techniques for addressing the PV effect are desired. An improvement is particularly important in CAD of polyps because the mucosa region of the colon, in which polyps often reside, is a boundary region which is often obscured by the PV effect. Thus, it is an object of the present method to provide an improved electronic cleansing process and, in particular, to provide an electronic cleansing process which results in a clean mucosa layer well-suited for CAD techniques.
SUMMARY OF THE INVENTION
[0007] In accordance with the present invention, a method for electronically cleansing a virtual object formed from acquired image data converted to a plurality of volume elements is provided. The present method allows individual volume elements, or voxels, to represent more than one material type. The method includes defining a partial volume image model for volume elements representing a plurality of material types based, at least in part, on the measured intensity value of the volume element. The material mixture for each of the volume elements representing a plurality of material types can be estimated using the observed intensity values and the defined partial volume image model. The volume elements representing a plurality of material types can then be classified in accordance with the estimated material mixture. For electronic colon cleansing, the method includes removing at least one classification of volume elements when displaying the virtual object.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a simplified flow chart illustrating the steps in one exemplary embodiment of the present method of electronic colon cleansing;
[0009] FIG. 2 is a simplified flow chart further representing the process of developing a PV or mixture image model, suitable for use with the present method;
[0010] FIG. 3 is a simplified flow chart further illustrating an exemplary process of PV segmentation of the mixture image in accordance with the present method;
[0011] FIG. 4A is an exemplary CT image slice of the colon, illustrating a layer of enhanced colonic materials. The dotted vertical line indicates a sample path for the density profile of FIG. 4C ;
[0012] FIG. 4B is an exemplary CT image slice of the colon that has been partially cleansed, leaving an interface layer intact;
[0013] FIG. 4C is an exemplary graph that shows the corresponding density profile of the exemplary CT image slice along the vertical line, illustrated in FIG. 4A ;
[0014] FIG. 4D is an exemplary graph that shows the corresponding density profile of the exemplary CT image slice in FIG. 4B , along the vertical line illustrated in FIG. 4A ;
[0015] FIG. 5A is an exemplary CT image slice illustrating the mixture-based PV segmentation result from the corresponding image slice of FIG. 4A ;
[0016] FIG. 5B is an exemplary graph that shows the corresponding mixture segmentation profiles for FIG. 5A for air, muscle and bone/tagged materials along the sample dotted vertical line which is the same as the line shown in FIG. 4A ;
[0017] FIG. 5C is an exemplary CT image slice that illustrates the border of volume S e (the entire colon lumen enclosure) by a white line enclosing the entire colon lumen;
[0018] FIG. 5D is the exemplary CT image slice of FIG. 5C that further shows the regions in the enclosed volume of the colon lumen, which results from segmentation and grouping;
[0019] FIG. 6A is an exemplary CT image slice (originally shown in FIG. 4A );
[0020] FIG. 6B is the CT image slice of FIG. 6A further showing the cleansed CT image after altering the density values and in which all the tagged colonic materials are removed;
[0021] FIG. 6C is the CT image slice of FIG. 6A that further illustrates the final cleansed CT image having a fully restored mucosa layer and a cleansed colon lumen;
[0022] FIG. 6D is an exemplary graph that shows the corresponding density profile of the CT image slice along the vertical line in FIG. 6A ;
[0023] FIG. 6E is a graph that shows the corresponding density profile of the CT image slice in FIG. 6B along the vertical line shown in FIG. 6A ;
[0024] FIG. 6F is a graph that shows the corresponding density profile of the CT image slice in FIG. 6C along the vertical line shown in FIG. 6A ;
[0025] FIG. 7 is a table that shows the various material mixtures that might be present in a voxel when four material types are present in a CT image;
[0026] FIG. 8 is a simplified flow chart illustrating the steps of the exemplary process of further classifying the voxels as parts of the volume of interest after PV segmentation.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0027] An overview of the present method is illustrated by reference to the simplified flow chart in FIG. 1 . An exemplary embodiment of the present invention assumes that, after proper bowel preparation, appropriate 2D image data has been acquired, such as through the use of a spiral CT scan, MRI scan, or other suitable method known in the art of virtual colonoscopy (step 100 ). From the 2D image data, the volume of interest (VOI), such as the colon tissue volume, is extracted in a manner generally known in the art (step 105 ). For example, a sliced spiral CT scanner can be used with clinically available protocols to cover the entire abdominal volume during a single breath hold. Suitable detector collimation can be 5 mm and the images can be reconstructed as 1 mm thick slices of 512×512 array size. An example of a CT image slice is illustrated in FIG. 4A . The exemplary 2D image in FIG. 4A has five distinct areas: air ( 400 ), an interface layer ( 405 ), colonic material ( 410 ), a mucosa layer ( 415 ), and colon tissue/bone ( 420 ). The present methods operate to classify the voxels in a region of interest, such as the colon, using a mixture-based image segmentation algorithm and to remove or reclassify the classification of colonic materials for a clean colon lumen and mucosa layer, resulting in the “cleansed” image in FIG. 6C .
[0028] Returning to FIG. 1 , in step 110 , the density values of each voxel are used to create a mixture image model, also represented herein as a PV image model. Further, in step 115 , the mixture image model is used in a PV segmentation algorithm, described in further detail below, to initially classify the various voxels of the acquired colon image. In step 120 , to address any misclassified voxels, the classified voxels are reclassified through a series of dilation and erosion operations in a manner generally known in the art, which are described in further detail below. Depending on a voxel's reclassification, in step 125 , the voxel may be grouped in different regions of similar density value. In step 130 , depending on its region, a voxel's density value can be altered, described in further detail below, to further classify the individual voxels as part of the volume of interest and subsequently restored. Further in step 130 , voxels grouped in some boundary regions are subjected to an iterative segmentation algorithm, described in further detail below, to further classify the voxels as part of the volume of interest.
[0029] Turning to steps 110 and 115 , prior to the virtual colon cleansing, the image voxels can be initially classified as containing one or more materials by using a mixture image segmentation algorithm, also known as a PV image segmentation algorithm. Mixture image segmentation operates to determine the material mixtures and the material model parameters from the acquired image data, which include observed density or intensity values. To achieve the goals of mixture image segmentation, the observed density or intensity values must relate in some way to the material mixtures and the material model parameters. The mixture image model in step 110 is used to establish the relationship between the measured intensity values and the mixture properties of each voxel so that there may be effective mixture image segmentation in step 115 .
[0030] FIG. 2 is a flow chart further illustrating the steps of creating a mixture image model. First, in step 200 , a relationship is established between what is observed, the measured intensity values for each voxel, and what is not observed, the density contribution of each material represented by a voxel. In the present exemplary embodiment, the acquired image density distribution Y can be represented by a column vector [y 1 , y 2 , . . . , y N ] T , where the observed density of an individual voxel i is y i and N is the total number of voxels in the image. If the acquired image density {y i } may possibly contain K material types within each voxel i, then there may be a possibility of K tissue types, where each material type k has a contribution x ik to the observed density value y i for an individual voxel i. Therefore, the observed density value y i can be represented by the relationship y i =Σ k=1 K x ik . The expression states that the sum of K density contributing elements x ik , for a particular voxel i, constitutes the observed density y i for a particular voxel i.
[0031] If there are multiple material types in at least some of the voxels, then a statistical determination of each material type's contribution to the individual voxel's intensity value is performed (step 205 ). Under the present exemplary embodiment, the unobservable density contributing element x ik is expected to follow a Gaussian statistical distribution with mean μ ik and variance σ ik 2 Voxel i may be fully filled by material type k; in which case x ik may become the observable variable y i in the present exemplary embodiment. If, however, voxel i is partially filled by material type k, then m ik may be the fraction of material type k inside voxel i. When there is a possibility of multiple material types, the resulting relationship can be expressed by
[0000]
μ
ik
=
def
m
ik
μ
k
and
σ
ik
2
=
def
m
ik
σ
k
2
,
where
∑
k
=
1
K
m
ik
=
1
,
0
≤
m
ik
≤
1
and
(
μ
k
,
σ
k
,
2
,
μ
ik
,
σ
ik
,
2
)
≥
0.
[0000] The image density y i at voxel i can be expressed as y i =ρ i Σ k=1 K m ik μ k +∈ i which follows a Gaussian distribution, where ∈ i is Gaussian noise associated with y i at voxel i with a mean of zero and a variance expressed as σ y i 2 =Σ k=1 K σ ik 2 =Σ k=1 K m ik σ k 2 . Notation ρ i reflects the bias field or inhomogeneity effect at voxel i which is a result of a non-uniform RF field across the body and tissue response to the local magnetic field. In a non-MRI scan, however, the ρ i factor may be removed.
[0032] The probability distribution of sampling {y i }, given the parameters {m ik , ρ i , μ k σ k 2 }, can be expressed as:
[0000]
Pr
(
Y
|
M
,
ρ
,
μ
,
σ
)
=
∏
i
=
1
N
Pr
(
y
i
|
m
i
,
ρ
,
μ
,
σ
)
=
∏
i
=
1
N
1
2
π
∑
k
=
1
K
m
ik
σ
k
2
exp
[
-
(
y
i
-
ρ
i
∑
k
=
1
K
m
ik
μ
k
)
2
2
∑
k
=
1
K
m
ik
σ
k
2
]
(
1
)
[0000] where M=[m 1 , m 2 , . . . , m N ] T , m i =[m i1 , m i2 , . . . , m iK ] T , μ=[μ 1 , μ 2 , . . . , μ K ] T , and σ 2 =[σ 1 2 , σ 2 2 , . . . , σ K 2 ] T . The probability distribution of sampling {x ik }, given the parameters {m ik , ρ i , μ k , σ k 2 } can be expressed as:
[0000]
Pr
(
X
|
m
,
ρ
,
μ
,
σ
)
=
∏
i
,
k
=
1
N
,
K
1
2
π
m
ik
σ
k
2
exp
[
-
(
x
ik
-
ρ
i
m
ik
μ
k
)
2
2
m
ik
σ
k
2
]
(
2
)
[0000] where X=[x 1 , x 2 , . . . , x N ] T and x i =[x i1 , x i2 , . . . , x iK ] T . Taken together, equations (1) and (2) represent a PV or mixture image model, which may be used in of mixture image segmentation in step 115 of FIG. 1 .
[0033] The mixture image segmentation determines the composition of material mixtures {m ik }, (Σ k=1 K m ik =1 and 0≦m ik ≦1), and the material model parameters {ρ i , μ k , σ k 2 } from the acquired image data {y i }. As described below, an expectation-maximization (EM) algorithm, which is generally known in the art, can be used to estimate the mixture parameters. The task of determining the mixture parameters {m ik , ρ i , μ k , σ k 2 }, given the acquired image data {y i }, can be specified by an a posteriori probability, which first requires an a priori distribution of {m ik } and {ρ i }.
[0034] In image processing applications, a Markov random field (MRF) a priori regularization can be use to determine a maximum a posteriori probability (MAP) solution. The MRF model for {m ik } can be expressed in the form:
[0000]
Pr
(
m
i
|
N
i
)
=
1
Z
exp
(
-
β
∑
k
=
1
,
j
∈
N
i
K
α
ij
(
m
ik
-
m
jk
)
2
(
3
)
[0000] where N i denotes the neighborhood of voxel i, β is a parameter controlling the degree of the penalty on the mixture M, α ij is a scale factor reflecting the difference among various orders of the neighboring voxels, and Z is the normalization factor for the MRF model.
[0035] In the present exemplary embodiment, only the first-order neighborhood system is considered and α ij is the same for the six first-order neighbors when the image has a uniform spatial resolution in three dimensions (e.g., α ij =1). When the axial resolution is two times lower than the transverse resolution, the α ij for the two neighbors in the axial direction is two times smaller than the α ij for the four neighbors in the transverse plane (e.g., α ij =1 in transverse plane and α ij =0.5 in axial direction).
[0036] A similar MRF can be specified for {ρ i } as:
[0000]
Pr
(
ρ
i
|
N
i
)
=
1
Z
exp
[
-
γ
1
∑
j
=
1
R
(
D
j
*
ρ
)
i
2
-
γ
2
∑
j
,
l
=
1
R
(
D
j
*
D
l
*
ρ
)
i
2
]
(
4
)
[0000] where R equals 2 for 2D slice images and 3 for 3D volume images. Notation D is the standard forward finite difference operator along the corresponding directions. The symbol * denotes the one dimensional discrete convolution operator. The first-order regularization term (associated with γ 1 ) penalizes a large variation in the bias field and the second-order regularization term (associated with γ 2 ) penalizes the discontinuities in the bias field {ρ i }. Both parameters γ 1 and γ 2 play a similar role as β, in the MRF for {m ik }, by controlling the degree of smoothness of the bias field. The conditional expectation in the EM algorithm, given the observed data {y i } and the estimate {M (n) , μ (n) , σ 2(n) } in the n th iteration, can be expressed by:
[0000]
Q
(
M
,
ρ
,
μ
,
σ
|
M
(
n
)
,
ρ
(
n
)
,
μ
(
n
)
,
σ
(
n
)
)
=
E
[
ln
Pr
(
X
|
M
,
ρ
,
μ
,
σ
)
|
Y
,
M
(
n
)
,
ρ
(
n
)
,
μ
(
n
)
,
σ
(
n
)
]
=
-
1
/
2
∑
i
=
1
,
k
=
1
N
,
K
{
[
ln
(
2
π
m
ik
σ
k
2
)
+
1
ω
ik
σ
k
2
(
x
ik
2
(
n
)
-
2
ρ
i
m
ik
μ
k
x
ik
(
n
)
+
ρ
i
2
m
ik
2
μ
k
2
)
]
+
2
β
∑
j
∈
N
i
α
ij
(
m
ik
-
m
jk
)
2
+
2
[
γ
1
∑
j
=
1
R
(
D
j
*
ρ
)
i
2
+
]
}
(
5
)
[0000] where the conditional means for x ik and x ik 2 can be expressed by:
[0000]
x
ik
(
n
)
=
E
[
x
ik
y
i
,
M
(
n
)
,
μ
(
n
)
,
σ
2
(
n
)
]
=
m
ik
(
n
)
μ
k
(
n
)
+
m
ik
(
n
)
σ
k
2
(
n
)
∑
j
=
1
K
m
ij
(
n
)
σ
j
2
(
n
)
·
(
y
i
-
∑
j
=
1
K
m
ij
(
n
)
μ
j
(
n
)
)
(
6
)
x
ik
2
(
n
)
=
E
[
x
ik
2
y
i
,
M
(
n
)
,
μ
(
n
)
,
σ
2
(
n
)
]
=
(
x
ik
(
n
)
)
2
+
m
ik
(
n
)
σ
k
2
(
n
)
∑
j
≠
k
K
m
ij
(
n
)
σ
j
2
(
n
)
∑
j
=
1
K
m
ij
(
n
)
σ
j
2
(
n
)
.
(
7
)
[0037] The maximization in the EM algorithm determines the estimate in the (n+1) th iteration, which maximizes the conditional expectation of equation (5). For the mixture model parameter {μ k }, the differential is
[0000]
∂
Q
(
.
)
/
∂
μ
k
μ
k
=
μ
k
(
n
+
1
)
=
0
,
[0000] which leads to:
[0000]
μ
k
(
n
+
1
)
=
∑
i
=
1
N
x
ik
(
n
)
∑
i
=
1
N
ρ
i
(
n
)
m
ik
(
n
)
(
8
)
[0000] For the other mixture model parameter {σ k 2 }, the relationship may be expressed by:
[0000]
σ
k
2
(
n
+
1
)
=
1
N
∑
i
=
1
N
x
ik
2
(
n
)
-
2
ρ
i
(
n
)
m
ik
(
n
)
μ
k
(
n
)
x
ik
(
n
)
+
ρ
i
(
n
)
m
ik
2
(
n
)
μ
k
2
(
n
)
m
ik
(
n
)
.
(
9
)
[0000] Maximizing the conditional expectation function Q(.) with respect to the tissue mixture parameter {m ik }, under the conditions of Σ k=1 K m ik =1 and 0≦m ik ≦1, does not generally have a closed-form solution like equations (6) and (7) have. When only a single acquired image {y i } is available, under the condition of Σ k=1 K m ik =1, the solution for the maximization of Q(.), if it exists, limits voxel i to having a maximum of two tissue types. When noise is present in the image, additional constraints may be needed for a regularization solution. Adding the MRF to equation (5) causes the conditional expectation of the posteriori to have a quadratic form when the distribution is at the n th iteration and the variance σ ik 2 =m ik σ k 2 is fixed for the (n+1) th iterated estimate. By maximizing the quadratic form Q(.)+Pr(m i |N i ) with respect to the material mixture parameter {m ik }, under the conditions of Σ k=1 K m ik =1 and 0≦m ik ≦1, a closed-form solution can be derived. In the case where each voxel is limited to a maximum of two tissue types, i.e., m i2 =1−m i1 , the resultant relationship can be expressed as:
[0000]
m
i
1
(
n
+
1
)
=
x
i
1
(
n
)
σ
i
2
2
(
n
)
μ
1
(
n
)
+
σ
i
1
2
(
n
)
μ
2
2
(
n
)
-
x
i
2
(
n
)
σ
i
1
2
(
n
)
μ
2
(
n
)
+
4
βσ
i
1
2
(
n
)
σ
i
2
2
(
n
)
∑
j
∈
N
i
α
ij
m
j
1
(
n
)
μ
1
2
(
n
)
σ
i
2
2
(
n
)
+
μ
2
2
(
n
)
σ
i
1
2
(
n
)
+
4
βσ
i
1
2
(
n
)
σ
i
2
2
(
n
)
∑
j
∈
N
i
α
ij
(
10
)
[0000] The bias field parameter {ρ i } can be expressed by:
[0000]
∑
k
=
1
K
μ
k
(
n
)
x
ik
(
n
)
σ
k
2
(
n
)
=
ρ
i
·
∑
k
=
1
K
m
ik
(
n
)
μ
k
2
(
n
)
σ
k
2
(
n
)
m
ik
(
n
)
μ
k
2
(
n
)
+
γ
1
(
H
1
*
ρ
)
i
+
γ
2
(
H
2
*
ρ
)
i
where
H
1
=
[
0
-
1
0
-
1
4
-
1
0
-
1
0
]
H
2
=
[
0
0
1
0
0
0
2
-
8
2
0
1
-
8
20
-
8
1
0
2
-
8
2
0
0
0
1
0
0
]
.
(
11
)
[0000] Solving equation (11) for {ρ i } can be performed using equation (10).
[0038] Equations (8), (9), (10), and, if needed, (11) provide a MAP-EM solution for mixture image segmentation when the mixture in each voxel is resolved to a maximum of two material types per voxel.
[0039] FIG. 3 is a simplified flow chart illustrating a PV segmentation process of step 120 using the MAP-EM solution of the PV image model derived above. Mixture image segmentation begins with an initial segmentation operation in step 305 involving a simple threshold operator, as known in the art, for hard segmentation. From the hard segmentation of step 300 , each voxel is initially classified as one of four initial tissue types (air, soft tissue, muscle, and bone/TM) or model parameter sets {μ k (0) , σ k 2(0) } using the labeled voxel density values. The initial tissue mixture {m ik (0) } assumes that each voxel is 100% occupied by a single predominant tissue type. Applying the initial estimates of step 300 , the MAP-EM solution set forth above in Equations 8-11 is then applied in step 305 . The results of consecutive iterations of the MAP-EM solution are tested for convergence to an acceptable value in step 310 . In one embodiment, convergance is assumed when the following termination criterion is satisfied:
[0000]
Max
(
μ
k
(
n
+
1
)
μ
k
(
n
)
-
1
k
=
1
,
2
)
<
γ
.
[0000] When the maximum difference between the means of each tissue class at the n th and the (n+1) th iterations is less than the specified threshold γ, the iteration process is terminated. In the present exemplary embodiment, γ is set to be 0.05.
[0040] Since the MAP-EM solution of Equations (8) through (11) only provides a closed form solution for identifying two material types per voxel, and since there is no limitation on the number of material types in an entire image, an additional process is used to constrain the analysis to two material types between iterations of the MAP-EM solution of Step 305 . In the present exemplary embodiment where the colon represents the volume of interest, the voxels of an image may be generally classified as containing four material types with different image densities, i.e., K=4: (i) air in the colon lumen and lungs, (ii) fat or soft tissues, (iii) muscle, and (iv) bone or tagged colonic materials. When there are four tissue types (the air, soft tissue, muscle, and bone/TM) expected to be present in an image, there are a total of 15 possible tissue mixtures, as shown in FIG. 7 . This knowledge of the region of interest can be used to constrain the voxel mixture to a maximum of two components.
[0041] Steps 315 through 325 , which are described below, can be used to limit each voxel to two material type mixtures which are compatible with the above described MAP-EM solution. In step 315 , the mixture estimate of each voxel is evaluated and the most dominant component is selected as the voxel type. A nearest neighbor analysis, such as evaluating the 6 first-order neighbors, can then be applied to each voxel to determine the tissue types of the voxel neighborhood in step 320 . The mixture for the voxel is then assigned as the two predominant types in the neighborhood in step 325 . For example, if three voxels of the first-order neighborhood where classified as air, two as bone/tagged materials and one was classified as muscle, the mixture for the voxel would be air and bone/TM. In the event that two tissue types are equally represented in the nearest neighbor analysis, the weights of the tissue types in the neighborhood voxels can be added and those components with the highest sum can be considered the predominant tissue types. For example, if two voxels were classified as air, two as muscle, and two voxels in the neighborhood classified as bone/TM, the values of air, muscle and bone/TM components in the mixtures of each voxel derived from the MAP-EM solution can be added to determine which are the two predominant tissue types in step 325 . After the two predominant tissue types are identified in step 325 , the PV image segmentation process returns to step 310 for another iteration of the MAP-EM solution. The process repeats until convergance of the MAP-EM solution is detected in step 310 , as described above.
[0042] The PV image segmentation process described above is applicable to the case where each voxel can be resolved to a maximum of two material types per voxel (i.e., N=2 in step 325 ). However, the present method can be extended to mixtures of three or more material types per voxel (i.e., N=3 or more in step 325 ). Regardless of the number of material types, equations (8) and (9) of the MAP-EM solution described above are applicable. However, when a voxel is to be resolved to mixtures of three or more material types, equation (10) no longer provides a solution for mixture image segmentation and a new expression for the mixture parameter must be derived.
[0043] With three material types, for example, the conditional expectation can be expressed as:
[0000]
Q
i
≈
1
2
∑
k
{
1
(
m
ik
σ
k
2
)
(
n
)
[
-
2
ρ
i
(
n
)
x
ik
(
n
)
m
ik
μ
k
(
n
)
+
ρ
i
2
(
n
)
m
ik
2
(
μ
k
(
n
)
)
2
]
+
2
β
∑
r
∈
N
i
α
ir
(
ω
ik
2
-
2
m
ik
m
rk
(
n
)
)
2
}
=
1
2
∑
k
{
m
ik
2
(
(
ρ
i
(
n
)
μ
k
(
n
)
)
2
(
m
ik
σ
k
2
)
(
n
)
+
2
β
∑
r
∈
ɛ
i
α
ir
)
}
-
∑
k
{
m
ik
(
ρ
i
(
n
)
x
ik
(
n
)
μ
k
(
n
)
(
m
ik
σ
k
2
)
(
n
)
+
2
β
∑
r
∈
ɛ
i
α
ir
m
rk
(
n
)
)
}
(
12
)
[0000] In matrix form, this be represented by:
[0000]
Q
i
≈
1
2
(
m
i
1
m
i
2
m
i
3
)
[
T
0
T
1
T
2
T
3
T
4
T
5
T
6
T
7
T
8
]
(
m
i
1
m
i
2
m
i
3
)
-
(
b
0
b
1
b
2
)
(
m
i
1
m
i
2
m
i
3
)
[0000] where T is a diagonal matrix that may be represented by:
[0000]
T
=
[
T
0
0
0
0
T
4
0
0
0
T
8
]
with
T
0
=
(
ρ
i
(
n
)
μ
1
(
n
)
)
2
(
m
i
1
σ
1
2
)
(
n
)
+
2
β
∑
r
∈
ɛ
i
α
ir
,
T
4
=
(
ρ
i
(
n
)
μ
2
(
n
)
)
2
(
m
i
2
σ
2
2
)
(
n
)
+
2
β
∑
r
∈
ɛ
i
α
ir
,
T
8
=
(
ρ
i
(
n
)
μ
3
(
n
)
)
2
(
m
i
3
σ
3
2
)
(
n
)
+
2
β
∑
r
∈
ɛ
i
α
ir
,
b
0
=
ρ
i
(
n
)
x
i
1
(
n
)
μ
1
(
n
)
(
m
i
1
σ
1
2
)
(
n
)
+
2
β
∑
r
∈
ɛ
i
α
ir
m
r
1
(
n
)
,
b
1
=
ρ
i
(
n
)
x
i
2
(
n
)
μ
2
(
n
)
(
m
i
2
σ
2
2
)
(
n
)
+
2
β
∑
r
∈
ɛ
i
α
ir
m
r
2
(
n
)
,
b
2
=
ρ
i
(
n
)
x
i
3
(
n
)
μ
3
(
n
)
(
m
i
3
σ
3
2
)
(
n
)
+
2
β
∑
r
∈
ɛ
i
α
ir
m
r
3
(
n
)
.
[0000] With the limitation set at a maximum three material types per voxel, the solution for the mixture parameter {m ik } becomes:
[0000]
{
m
i
1
+
m
i
2
+
m
i
3
=
1
m
i
1
(
T
0
-
T
1
)
+
m
i
2
(
T
3
-
T
4
)
+
m
i
3
(
T
6
-
T
7
)
=
b
0
-
b
1
m
i
1
(
T
0
-
T
2
)
+
m
i
2
(
T
3
-
T
5
)
+
m
i
3
(
T
6
-
T
8
)
=
b
0
-
b
2
(
13
)
[0000] The same derivation can be repeated to obtain similar equations for the solution of the mixture parameter {m ik } when the limitation is four or more material types per voxel.
[0044] Referring again to FIG. 1 , after the iterative PV or mixture image segmentation of step 115 is completed, the voxels in the colon lumen may be classified as air, mixture of air with tissue, mixture of air with tagged materials, or mixture of tissue with tagged materials. Once the voxels are initially classified by mixture image segmentation, the present electronic colon cleansing (ECC) method applies this information to remove undesired components and to present a clean colon lumen and mucosa layer.
[0045] In most cases, PV image segmentation of FIG. 3 provides correct tissue/material mixtures within the interface and mucosa layers. In some cases, however, PV image segmentation may identify an incorrect mixture component in these layers. In step 120 , voxels in the colon lumen may be reclassified to reduce such misclassification. FIG. 5B shows an example of such incorrectly segmented mixtures in voxels around location 30 along the vertical profile 530 . The peak around location 30 along the vertical profile (the interface layer) indicates a misidentification of voxels 530 . Around location 30 , the graph indicates that the voxel contains a mixture of muscle material, colon air, and bone/TM. However, at the air/tagged materials interface layer, there is no possibility of muscle being present, therefore such a classification can be considered a misclassification.
[0046] In order to avoid such incorrect identifications, the present exemplary embodiment utilizes the well-known dilation-erosion strategy, such as described in “Digital Image Processing,” Gonzalez et al., Addison-Wesley (1992), to reclassify potentially misclassified voxels. In the reclassification strategy of step 120 , as implemented in the present exemplary embodiment, the colon air segmentation volume may be represented by S a , which consists of the air component {m air } in the voxel array. Further, the tagged colonic material segmentation volume may be represented by S t . For each volume, a 3D dilation operation may be applied by a three-cubic strel matrix:
[0000] D a 32 Dilation( S a ,strel), D t =Dilation( S t ,strel),strel=[1 1 1] T ·[1 1 1]. (14)
[0000] A new volume S e may be constructed by applying the erosion operation on the sum of D a and D t , i.e., S e =Erosion ((D a +D t ), strel). After the reclassification of the voxels, the voxels are classified correctly as air, a mixture of air/TM, or TM.
[0047] Step 125 may include grouping of like voxels in regions according to their mixture type. The grouping of voxels facilitates the subsequent steps of ECC by establishing the various regions in the acquired image according to the group. The new erosion volume S e , established in step 120 , covers the entire colonic space including the tagged material region and the interface layer, as shown by the enclosed white cylindrical boarder 535 in FIG. 5C . Based on the three volumes D a , D t , and S e , the entire colonic space may be divided into three regions according to the following criteria
[0000] P m ={voxel i |S i e >0 ,D i a >0 ,D i t >0}
[0000] P a ={voxel i |vowel i ∉P m ,S i e >0 ,S i a >0 ,S i t =0}
[0000] P t ={voxel i |vowel i ∉P m ,S i e >S i e =0 ,S i t >0} (15)
[0000] where P a represents the colonic air space of region 1515 in FIG. 5D , P t reflects the tagged material region III 525 in FIG. 5D , and P m indicates the interface layer region II 520 .
[0048] Step 130 may include further classifications of certain voxels as different parts of the volume of interest (VOI). Referring to FIG. 8 , in the present exemplary embodiment, any voxels comprising the air space may be classified as part of the lumen in the VOI 800 . In the present exemplary embodiment where the VOI is a colon, the open space would be the colon lumen. Following the air space classification, various interface layers can be identified 805 . Interface layers may include zones at the border of different regions, which include voxels having a mixture of material types representative of the neighboring materials. In the present exemplary embodiment, where the VOI is a colon, there may be two interface layers. Referring to FIG. 4A , the first interface layer is an enhanced mucosa layer (“the mucosa layer”) 415 consisting of a mixture of colon tissues and tagged materials, represented in FIG. 4C and FIG. 4D . The present ECC method identifies the enhanced mucosa layer and removes the portion with tagged colonic materials.
[0049] The second interface layer 405 in the present exemplary embodiment is the layer that can be presented between the air layer and the tagged materials layer as seen in FIG. 4A and FIG. 4C . Due to the PV effect and other potential errors such as from the scanner, patient motion, and image reconstruction procedure, the image density at the interface layer 405 may vary from the low end of about −900 HU, for air, to the high end of about 400 HU, for enhanced residues, as depicted in FIG. 4C . A simple threshold approach, as known in the art, can be applied to remove a substantial portion of tagged colonic materials. However, since the second interface layer 405 exhibits density values which overlap the range of colon tissues, it is difficult to distinguish the voxels of colonic materials in this layer from that of the colon tissues based on density value alone. As illustrated in FIG. 4B , applying a simple threshold, such as 200 HU, removes the majority of tagged colonic materials, but an interface layer 425 is retained.
[0050] Referring to FIG. 5D , three regions may be identified as parts of the colon or colon lumen. Region I consists entirely of the colonic air space and, as stated above, may be classified as the colon lumen in step 800 . However, before voxels in regions II and III may be classified as part of the colon, their image density values I i new may be altered by a density altering function in step 810 :
[0000]
I
i
new
=
{
I
i
original
+
(
μ
1
-
μ
4
)
·
m
i
4
+
(
I
_
i
-
I
i
original
)
·
m
i
4
if
I
_
i
≥
I
i
original
I
i
original
+
(
μ
1
-
μ
4
)
·
(
m
i
4
+
(
I
i
original
-
I
_
i
)
·
m
i
4
μ
4
)
if
I
_
i
<
I
i
original
(
16
)
[0000] where Ī i =Σ k=1 4 m ik μ k , and μ k and m ik have been defined before as the mean parameter of material type k in the image and the fraction of material type k in voxel i respectively In equation (16), index 1 refers to the segmentation of colonic air and index 4 refers to the segmentation of the bone/TM.
[0051] Using equation (16), the image density values of the voxels in regions II and III are altered. The voxels with altered density values may then be classified in step 815 . In region III, the altered image density values of those voxels containing mixtures of colon tissues and tagged materials are restored to form the mucosa layer, and other voxels are classified as colon lumen voxels. In region II, the voxels on each side (or at each boundary) of the interface layer are altered by equation (16), but may not be completely restored due to the presence of more than two tissue types in some voxels. Referring to FIGS. 6B and 6E , some small spots may be retained along the horizontal direction in region II 600 after processing by equation (16).
[0052] To eliminate this patch-like effect, the present exemplary embodiment introduces an equation to restore the image density for each voxel in region II. First, a subtraction volume SUB may be defined, which is generated by iteration:
[0000]
SUB
i
(
0
)
=
I
i
new
SUB
i
(
n
)
=
SUB
i
(
n
-
1
)
+
∑
n
∈
neighbor
(
i
)
-
(
∇
n
SUB
(
n
-
1
)
)
2
·
∇
n
SUB
(
n
-
1
)
(
17
)
[0000] where ∇ represents the first-order derivative at the given position and the neighborhood of this voxel includes that voxel itself. In the present exemplary embodiment, after three iterations of equation (17), the image density at the interface layer may be further adjusted by I i newII =I i new −SUB i , i ∈ interface layer. The image density values in the interface layer may then be reduced to a reasonable level I i newII toward that of air level. Those voxels which exhibit modified density values, having a value close to that of air, are then classified as the colon lumen space in step 835 . These operations remove the patch-like effect and improve the image density restoration at both ends of region II, as shown in FIG. 6C and FIG. 6F .
[0053] The converted air voxels in regions I, II, and III make up the colon lumen space, from which a virtual colon model may be constructed for VC examination. Within the colon lumen space, a centerline or fly-path may be determined and a potential field may be constructed to facilitate the VC navigation through the entire lumen space to facilitate looking for polyps, as known in the art. The geometric information of the lumen border can be analyzed by a surface-based CAD technique to detect the polyps, as known in the art. The restored image density values of the mucosa layer, which may be comprised of five to ten voxels beyond the lumen border, can be extracted for texture analysis for improved CAD performance, according to the art. | A method for electronically cleansing a virtual object formed from acquired image data converted to a plurality of volume elements is provided. The present method allows individual volume elements, or voxels, to represent more than one material type. The method includes defining a partial volume image model for volume elements representing a plurality of material types based, at least in part, on the measured intensity value of the volume element. The material mixture for each of the volume elements representing a plurality of material types can be estimated using the observed intensity values and the defined partial volume image model. The volume elements representing a plurality of material types can then be classified in accordance with the estimated material mixture. For electronic colon cleansing, the method includes removing at least one classification of volume elements when displaying the virtual object. | 6 |
BACKGROUND OF THE INVENTION
This invention relates generally to a rolling bearing and, more particularly, to a bearing equipped with a data sensor device which can be oriented and which includes an encoding element moveable in front of a sensor mounted on a sensor support.
Reference EP-A 453,331 describes a bearing having a sensor support which has machined parts and carries means for fastening a sensor by a hook engaging a bearing ring. The present invention relates to a simplification of the construction of such a sensor support.
The foregoing illustrates limitations known to exist in present roller bearings with sensors. Thus, it is apparent that it would be advantageous to provide an alternative directed to overcoming one or more of the limitations set forth above. Accordingly, a suitable alternative is provided including features more fully disclosed hereinafter.
SUMMARY OF THE INVENTION
In one aspect of the present invention, this is accomplished by providing a bearing having a data sensor device comprising a stationary bearing ring, a rotatable bearing ring, a sensor support having a slide, and axial positioning means on the sensor support in engagement with the stationary bearing ring for axially retaining the sensor support. A sensor is slidably mounted in the slide of the sensor support, and clamping means is provided for biasing the sensor into contact with the sensor support and for radially retaining the sensor in the slide. An encoding element is carried by the rotatable bearing ring and is rotatable in front of the sensor.
The foregoing and other aspects will become apparent from the following detailed description of the invention when considered in conjunction with the accompanying drawing figures.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
FIG. 1 is an axial cross-section along line I of FIG. 2 of a bearing equipped with a sensor support illustrating a first embodiment of the present invention;
FIG. 2 is a partial front view of the bearing shown of FIG. 1;
FIG. 3 is an enlarged cross-sectional view of the bearing of FIG. 1 showing the mounting zone of the sensor support on the bearing ring;
FIG. 4 is a front view of a sensor support illustrating first and second embodiments of the present invention;
FIG. 5 is an axial cross-sectional view of a bearing and sensor support illustrating a third embodiment of the present invention;
FIG. 6 is a front view of the sensor and sensor support of FIG. 5.
FIG. 7 is a cross-sectional view of the sensor and sensor support of FIG. 5 taken along the line VII--VII of FIG. 6;
FIG. 8 is a front view of a sensor and sensor support illustrating a fourth embodiment of the present invention;
FIG. 9 is a radial cross-section of a sensor support illustrating a fifth embodiment of the present invention;
FIG. 10 is an enlarged partial cross-section of the sensor support of FIG. 9; and
FIG. 11 is a perspective view illustrating a portion of the sensor support of FIG. 9.
DETAILED DESCRIPTION
Referring now to the drawings, FIGS. 1 and 2 illustrate a bearing 10 having an internal rotatable bearing ring 1 divided into two parts, an external stationary bearing ring 2, and rolling elements 3 positioned between the bearing rings. The bearing 10 may be sealed, for example by means of two fittings 4 with preassembled sealing lips as described in reference FR-A 2,505,951. The bearing 10 is intended to be used as a bearing in conventional assemblies, such as those described in reference EP-A 453,331.
A data sensor device of the present invention comprises a sensor 11 and an encoding element 12, which is integrally connected so that encoding element 12 rotates with the rotatable bearing ring 1 by means of a deflector 5 of the sealing fitting 4. The sensor 11 is contained in a mounting head 110 whose sides perform the function of guidance, for example by means of grooves 111. The front side of the head 110 carries a transverse groove 112 intended to receive a retention and positioning rib of the mounting head 110 of the sensor 11 on a ring-shaped sensor support 20 whose embodiment variants are shown in FIGS. 4 and 9.
According to FIG. 4, the sensor support consists of a ring-shaped disk made of cut sheet metal whose external edge 21 is folded axially to cover its circular mounting bearing surface limited by the lateral side of the stationary bearing ring 2. For this purpose and according to FIG. 3, the stationary bearing ring 2 carries a machined groove 22 which is limited axially by a conical abutment surface 23 which extends axially from an assembly ramp 24 with conical surface whose external diameter is adjacent to the bearing surface 23.
According to a first embodiment of the sensor support 20, the latter has zones 25 which are cut by punching, and which are distributed angularly at the periphery of the disk and at the surface of its external margin 21. The axial extremity of the margin 21 thus delimits with each zone such as 25 a resilient bar 26 for the axial positioning of the sensor support 20 in contact with the stationary bearing ring, which is bent radially in the direction of the bottom of the groove 22.
The right hand side of FIG. 4 shows bars sectioned into two parts to form attachment tabs 27, 27' which are bent along the cord of the cut zone 25 and which also ensure the axial positioning of the sensor support 20 in contact with the stationary bearing ring. The left hand side of FIG. 4 shows resilient bars 26 which are bent as before and which provide a radial force of the bar 26 in the groove 22. As shown in FIG. 4, the sensor support 20 carries a slide 30 for mounting the grooved head of the sensor 11. The parallel margins of the slide 30 are made by punching and symmetrical folding of two small tongues of tabs formed in the ring-shaped part of the sensor support 20.
To immobilize the sensor 11 on the sensor support 20, a clamp 31 is used, which is made of a spring wire whose resilient branches 32 are segments of wire which have been folded and are attached to the sensor support 20 at the extremity of the slide 30. A portion 33 of the clamp 31 extends between the branches 32 and constitutes a retention rib of the head 110 of the sensor in contact with the groove 112. As shown in FIG. 2, each branch 32 extends in part starting from its point of attachment 34 along the rear of the slide 30, then at the front of the slide 30 to define together with the rib 33 the clamping means for biasing the sensor 11 into contact with the sensor support 20.
FIG. 5 describes an embodiment variant of the bearing equipped with the sensor device. The external rotating bearing ring 1 is made of a single piece while the stationary internal ring 2 is made of two parts. FIG. 5 and FIGS. 6 through 10 are more specifically directed to the ring-shaped sensor support 20 and show the elements and devices already described with reference to FIGS. 1 and 2 and, therefore, have the same reference numbers.
As has been shown more particularly in FIGS. 5, 9, 10 and 11, the sensor support 20 may be made by embossing and punching. The sensor support 20 may be mounted temporarily on the bearing 10 together with the sensor 11. For this purpose, the side of the sensor support 20 turned towards the bearing may be cemented onto the bearing ring 2 for facilitating the mounting of the bearing equipped with the sensor device directly on a carrying shaft 9.
The head 110 of the sensor is mounted on the sensor support 20 which has a ring-shaped groove 40 which is embossed on the surface of the sensor support 20 as shown in FIGS. 9 and 11. The bottom of the groove 40 is punched locally and has a cut-out section 41 to which are connected a small tongue and resilient tabs 42 whose extremity carries a protrusion or a rib 43 for radial retention of the head 110 of the sensor in contact with the groove 112. In this configuration the lateral parallel margins of the cut-out section 41 constitute slides for the mounting of the head 110. The radial retention of the head 110 is achieved as described with reference to FIGS. 1 and 2.
FIG. 6 describes a retention segment 33 of the sensor head 110. The segment 33 is part of an expandable resilient ring engaging mounting tabs 44 distributed circumferentially on the front of the sensor support 20 and intended to retain portions of spring wire distributed at the periphery of the ring. According to FIG. 8, the segment 33 is a part of the spring wire which is shaped and carries attachment segments 45 of the branches 32 in contact with the sensor support 20.
As shown in the drawing, all the retention means of the sensor, such as the resilient bars 26 and the small tongues or resilient tabs 42, may be formed by local deformation of the constitutive material of the sensor support 20 during conventional punching operations.
According to the present invention, the sensor support carries means for axial positioning in contact with the stationary bearing ring. Clamping means is provided for maintaining contact of the sensor with the sensor support and for radial immobilization of the sensor in the slide. The sensor support may consist of a ring-shaped disk which has cut-out zones and functional deformations which are located in said zones for the purpose of immobilizing and positioning the sensor in the slide. | A stationary bearing ring, a rotatable bearing ring, and a sensor support having a slide are provided. The sensor support is axially retained in engagement with the stationary bearing ring, and a sensor is slidably mounted in the slide of the sensor support. The sensor is biased into contact with the sensor support and is radially retained in the slide. An encoding element is carried by the rotatable bearing ring and is rotatable in front of the sensor. Various embodiments are disclosed. | 5 |
BACKGROUND OF THE INVENTION
The present invention relates to the low and medium consistency refining of lignocellulosic material, and more particularly, to the control of the refining gap between relatively rotating refiner plates in such refiners.
Low consistency refiners for lignocellulosic material are used for developing fiber to increase surface area and fibrils and for cutting fibers to reduce their length. Low consistency refining was generally understood with respect to lignocellulosic material, as referring to a refiner fed by pumped slurry having a consistency of about 2-5% fiber. Modern pumping techniques accommodate consistency up to about 16% fiber (sometimes referred to as "medium consistency"). In these types of refiners, flow control is accomplished on the discharge of the machine, by a single throttling valve in a single discharge line. This is in contrast to the control of so-called high consistency refiners, where the feed is metered by a device upstream of the refiner. As used herein, "low consistency" should be understood as referring to pumped slurry with flow control at the discharge, as distinguished from high consistency with upstream metering.
Conventional two zone refiners maintain a common discharge from both refining zones and therefore, small differences in the refiner plate bar depth between the two zones or other factors can change the relative pumping capability of each zone. This can result in one zone pulling more than one-half of the total flow being supplied to the refiner which then provides uneven refining in the two zones since the thrust in the zones and the power applied is equal. Another deficiency is that the zone with the lower flow will have a smaller operating gap and therefore have a greater tendency for plate contact and increased wearing of the refining plate surfaces. This problem of uneven flow is particularly noticeable at material flows that are at the minimum volumetric capacity of the machine where operation may be desirable due to the lower refining intensities available at the lower flows.
SUMMARY OF THE INVENTION
The present invention is an improvement to low consistency refiners which treat fiber within a casing having a rotor member with first and second grinding faces opposed to respective third and fourth grinding faces, thereby establishing first and second grinding gaps, e.g., first and second refining zones. In such apparatus for refining a low consistency fibrous slurry, which includes a plurality of refining zones within a casing, the improvement comprises providing a unique discharge flow path from each refining zone to a respective unique discharge line out of the casing, and means for differentially adjusting the flow rate in each discharge line.
In accordance with the preferred embodiment of the invention, a divider is provided between the casing and the rotor member, thus dividing the discharge between the two refining gaps, into two separate flow streams. The two flow streams are discharged through separate nozzles from the refiner casing, and a separate flow control valve is installed in each discharge line. The first and second gaps are monitored in any conventional manner. In general, one face of each gap is movable axially relative to the opposed face of the same gap, i.e., the two gaps are variable. Under operating conditions, the flow control valves are adjusted for combined flow from the refiner casing as required by the production demands. However, the relative positioning between the two valves is adjusted until the refining gap measurements show equal gaps (within a pre-established tolerance) in the two refining zones.
The individual discharge from the two refining zones allows separate flow control for the two discharge streams and the flow can be adjusted until the refining gaps on each side are even. Adjustment of the outflow of refined fibers from the refiner changes the pressure in the refiner and between the grinding faces. By changing this pressure, the refining gaps can be increased or decreased, depending on whether outflow is increased or restricted. Restricting outflow drives up pressure and increases the refining gap. Allowing greater outflow results in decreased pressure and a smaller gap. The adjustment assures equal operating gaps. The refining action in the two zones is then assured of being equal resulting in a more constant pulp quality. Also, with the two refining zones being equal, it is feasible to operate the machine at a lower refining gap since one gap is not smaller than the other thus improving machine control and allowing higher potential refining capacity for the machine. Also, with equal refining gaps the potential for premature wearing of the refiner plates on the one side of the machine is eliminated. This improves refining plate life, thus lowering the cost of the refining plates, and limits the number of plate changes that need to be made, thus improving the machine availability and minimizing downtime. The invention also prevents changes in pulp quality as the plates wear.
It should also be understood that this configuration could be incorporated into machines with more than two refining zones, where again each of the refining gaps is monitored individually and adjusted by separate flow controls on respective separate discharges.
The invention may also be implemented in the embodiment of two refiners in series, where the split discharge flow from the first machine remains split and is fed to two separate sides of a second refiner. The second refiner may have a single or split discharge, feeding to a storage chest. In this embodiment, the control of discharge flow may be primarily concerned with equalization in the two discharge lines from the first refiner, so that the feed into each side of the second refiner (without the further assistance of pumps), would be equal. In other words, control on the first refiner would be to equalize the discharge flow, rather than to equalize refining gaps. The control on the two discharge lines of the second refiner, could be optimized for gap equalization, or flow equalization.
In alternative embodiments, the multiple refining gaps within the refiner can be substantially equalized without explicit gap measurement, but with a somewhat lesser degree of confidence, by differentially adjusting the valves on the respective dedicated discharge lines, to equalize either a measured pressure in each discharge line, or a measured flow rate in each discharge line. In the preferred control system, where direct gap measurements are taken, the differential adjustment in the discharge lines can be limited to avoid excessive adjustment which would result in the gap narrowing beyond a certain pre-established minimum value. In refiners where gap measurement is not made, or the adjustment on the discharge lines in accordance with the invention is not dependent on gap measurements, the operator would still achieve an advantage relative to conventional control.
It should be further appreciated that the present invention achieves gap equalization as a result of the variability of the gaps, to pressure imbalances within the refiner. In a number of refiners where the present invention may be utilized, the rotor is axially free floating. Thus, even if the stator plates are not adjustable during operation, the differential effect on the flow rate through each refining gap resulting from the differential adjustment of the valves in accordance with the invention, will produce axial realignment of the rotor, thereby achieving substantially equal gap width. For purposes of refining quality, the two most important factors are the energy power input (e.g. kilowatts) and the gap width. It can be appreciated that in some refiners, the stator plate is adjustable during operation and may also respond by moving axially as a result of the adjustments in differential flow rates in accordance with the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other objects and advantages of the invention will be evident from the following description and accompanying drawings, in which:
FIG. 1 is a side view, in section, of the central portion of one type of refiner having a flat central rotor with axial feeding and substantially radial refining in symmetric fashion about a vertical plane passing centrally through the rotor, as adapted with distinct discharge openings in the casing, in accordance with one embodiment of the present invention;
FIG. 2 is a section view similar to FIG. 1, for a second embodiment having a flat rotor between a fixed refining surface on one side and an axially adjustable refining surface on the other side, and the associated distinct casing discharge openings in accordance with a second embodiment of the invention;
FIG. 3 is a schematic representation of the preferred control system for the refiner depicted in FIG. 2;
FIG. 4 is a schematic representation of the preferred control logic associated with the control system shown in FIG. 3;
FIG. 5 is a section view of a portion of a third type of refiner in accordance with the present invention, wherein the rotor member has the form of two converging cones, each conical refining zone having its own associated discharge opening in the casing;
FIG. 6 is a section view of a portion of a fourth type of refiner in accordance with the present invention, wherein the rotor member has the form of two diverging cones, each conical refining zone having its own associated discharge opening in the casing; and
FIG. 7 is a schematic representation of a refiner system in which two refiners in series have the distinct discharge lines in accordance with the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
It should be understood that the present invention is applicable to a variety of refiners for mechanically treating a slurry of fibrous material, wherein the machine has at least two refining zones located substantially symmetrically on either side of a vertical plane perpendicular to the refiner shaft. A first refiner 10 of this type is shown in FIG. 1. A casing 12 has a substantially flat rotor 14 situated therein, the rotor carrying a first annular plate defining a first grinding face 16 and a second annular plate defining a second grinding surface 18. The rotor 14 is substantially parallel to and symmetric on either side of, a vertical plane indicated at 20. A shaft 22 extends horizontally about a rotation axis 24 and is driven at one or both ends (not shown) in a conventional manner. The refiner in FIG. 1 is in all respects pertinent to this disclosure, symmetric about plane 20, and therefore any structure described herein on one side of the plane, has counterpart structure on the other side of the plane.
A feed conduit 26 delivers a pumped slurry of lignocellulosic feed material through inlet opening 30 on either side of the casing 12. At the rotor, the material is re-directed radially outward through the transition region 32 whereupon it moves along the first grinding face 16 and a third grinding face 34 juxtaposed to the first face so as to define a first refining gap 38 therebetween. Similarly, on the other side of the rotor 14, material passes through the gap 40 formed between the second grinding face 18 and the juxtaposed grinding face 36.
A divider member 42 extends from the casing 12 to the periphery, i.e., circumference 44, of rotor 14, thereby maintaining separation between the refined fibers emerging from the first refining gap 38, relative to the refined fibers emerging from the second refining gap 40. The fibers from the first refining gap 38 are discharged from the casing through discharge opening 46, along discharge stream or line 56, whereas the fibers from the second refining gap 40 are discharged from the casing through opening 48 along discharge line 58.
It should be appreciated that the gaps 38, 40 are variable, in the sense that during the refiner operation, forces arise which tend to push the opposed faces 16,34 and 18,36, away from each other. Conventionally, the grinding faces 34,36 are mounted in stator rings which are urged inwardly, toward the rotor 14, by means of piston or other forces as indicated at 52,52'. The control of the gap width is an important aspect of producing fiber of desired quality. Accordingly, gap sensors such as shown at 50,54, can be provided to generate input signals to the controller for the stator movement indicated at 52.
Although the refiner structure is normally symmetric in the embodiment shown in FIG. 1, the widths of refining gaps 38,40 may not be equal, due for example, to the inherent fluctuations in the feed rates from the two sides of the rotor 14. In accordance with the present invention, differences in the gap widths 38,40, for example, as measured with sensors 50,54, are utilized to adjust at least one of the first and second flow rates 56,58, to thereby vary the width of at least one of the refining gaps. In the invention, the refining gap 40 is not regulated by controlling the stator 51, but by regulating the pressure in the refiner 10 and therefore on the grinding faces 16,18,34,36 by adjusting the outflow of refined fibers. In particular, at least one of the gap widths is adjusted so that the widths of the gaps 38,40, are equal, within a predetermined tolerance. This is preferably accomplished by a control valve 57,59 in each of the lines 56,58, responsive to the gap width sensor signals, in a manner to be described in greater detail in connection with FIGS. 2 and 3.
FIG. 2 shows a second embodiment 100 of a refiner in accordance with the present invention, having a casing 102 with a rotor 104 driven by a shaft 105. The rotor 104 carries a first annular plate 106 and, on the opposite side, a second annular plate 108. A third grinding plate 110 is supported in fixed relation by a support member 112 which is in turn affixed to the casing 102. The grinding face 114 of plate 106 is juxtaposed with the grinding face 116 in plate 110, thereby defining a first refining gap 118. A stator member 120 on the opposite side of rotor 104, carries a stator plate 122 with grinding surface 124 which is juxtaposed with plate 108 with grinding surface 127 and forms a second refining gap 128 therebetween. The stator ring 120 is conventionally adjustable by hydraulic or other means, axially toward and away from the rotor 104, as shown at 126. The rotor 104, although rigidly supported by the shaft, is itself moveable axially, because the shaft is supported in bearings which enable the shaft to adjust axially in response to the pressure balance between gaps 128 and 118. Whereas in the embodiment of FIG. 1, the rotor 14 remains axially fixed and the two stator rings 51,51' are adjustable as shown at 54, in the embodiment of FIG. 2, the stator ring 120 and rotor 104 are axially adjustable as shown at 126, while plate 110 is fixed relative to casing 102.
It should also be appreciated that in the embodiment of FIG. 2, the feed material is pumped as a slurry to the right of the rotor. Passageways 129,131 provided at the base of the rotor, permit the feedstream to split between the first stream that passes radially upward through the first refining gap 118, and a second stream which, after passage through the rotor base, travels radially outward through refining gap 128. In the embodiment of FIG. 2, the first gap 118 is alternatively referred to as being on the motor end of the refiner, whereas the gap 128 is considered at the adjustment end of the refiner.
As in the embodiment of FIG. 1, a divider ring 132 extends annularly from the casing 102 to the circumferential periphery 130 of the rotor 104. In the embodiment of FIG. 2, the annular ring 132 is welded at 136 perpendicularly to a plurality of horizontally extending legs 134, through which bolts 138 are secured to the casing 102. The divider 132 therefore maintains separation of the refined fiber emerging gap 118 and flowing through the first discharge opening 140 in casing 102, and the refined fiber emerging from gap 128 for discharge through the second opening 142 in casing 102. Flow control for each discharge stream is achieved by valves 141,143. Gap sensors 144 and 146 are provided through the fixed plate 110 and the stator plate 122, for generating respective gap width signals along lines 148,150, respectively.
FIG. 3 shows the control system in the preferred embodiment of the invention associated with FIG. 2. The refiner 100 has the first discharge opening 140 and second discharge opening 142, and a feed material inlet nozzle 160. The material fed to the two refining gaps 118,128 of FIG. 2, would be delivered by a pump, with a portion passing radially through gap 128 and a portion passing through openings in the rotor 104 and thereupon entering gap 118, in a conventional manner.
The signals commensurate with the gap widths 118,128 of FIG. 2, are transmitted along lines 148,150, to a control center shown generally at 172 in FIG. 3. The control center 172 also receives signals commensurate with the flow rate through each of the discharge openings 140,142. For example, the discharge through opening 140 is conveyed through line 176, valve 180, and flow transmitter 182, whereupon the flow signal is delivered on the line 183 indicated by Flow 1 to control station 172. Similarly, the material discharged through opening 142 passes through valve 184 and flow transmitter 186 in line 178, with the flow signal entering the control station 172 along line 173 labelled Flow 2. Among other control functions, the control station 172 monitors that the total flow rate discharged from the refiner 100 (i.e., as measured by signals Flow 1 and Flow 2), is equal to the total flow demand at refined fiber chest 179 (within a predetermined tolerance). This total demand may be a function of the power imparted to the fibers as indicated by the electric utilization delivered along the kilowatt line 174.
In accordance with the present invention, the gap widths are equalized, within a predetermined tolerance, by adjusting one or both of the flow rates via the control signal 190 delivered to valve 180, and/or 192 delivered to valve 184. This gap control can be used with or without the stator axial adjustment, i.e., "open" or "close" control signal 126. In other words, conventional gap control logic can be utilized to control overall refiner load and therefore pulp quality, whereas the discharge flow control equalizes the gaps. In this respect, transmitter 188 controls the overall (total) openings of valves 180 and 184, and therefore the total flow. The gap measurement signals control the relative relationships of the valves. If gap 1 is smaller than gap 2, then discharge valve 180 will open and discharge valve 184 close an equal amount, to thereby equalize the gap and maintain the same total flow from the refiner.
This is preferably accomplished using the control logic 200 shown in FIG. 4. An output signal on 148 indicative of the motor end position is delivered to functional block 202, as is a signal from line 150 indicative of the adjustment end position. In block 202, the motor end position is divided by the adjustment end position and an output is delivered to functional block 212. The motor end position signal from line 148 is also delivered to functional block 204, which defines the minimum position limits. In a similar manner, functional block 206 receives signals from lines 148 and 150, to divide the adjustment end position by the motor end position, and delivers a signal to functional block 210. The minimum position limit for the adjustment end is also defined in block 208.
The level transmitter 188 from the refined chest 179 delivers a signal to the functional block 214, which is the normal control block, as would be used conventionally, to control the total flow by adjusting a throttle valve in the single discharge line of the refiner. In the present invention, the output from the control loop block 214 is delivered to a multiplies 216, which receives a multiplying factor (typically 0.5) from functional block 218. In the manner to be described below, this results in one-half of the output signal from the control loop block 214, ultimately going to each of the valves 180, 184, whereby the total output of the two valves would be the same as that of a single valve in a conventional control system.
Each of the functional blocks 210,212 multiplies the output from the division in blocks 206 and 202, respectively, by the valve control signal from functional block 216. The output of functional block 210 is further modified via the logic of functional blocks 220, 222, which imposes limits to prevent the valve 180 from closing beyond the minimum position limit established in functional block 204. A similar limit on valve 184 is achieved by the effect of functional blocks 224 and 226 on the output signal from functional block 212.
Therefore, the logic scheme described in connection with FIG. 4, maintains simultaneous control of the flow through valves 180 and 184, while partitioning the flow between these valves to equalize the refining gaps derived from the motor end position signals 148 and adjustment end position signals 150.
Other aspects of the control system are preferably also implemented as shown in FIG. 3. Starting at the left, unrefined feed material is supplied from a chest 152 along line 168 to pump 154 for delivery through a consistency regulator 156 and line 158 to the feed inlet nozzle 160 of the refiner 100. A pressure sensor 162 in line 158 provides an input signal by which a valve 164 affects the pressure in line 168. In response to the consistency regulator signal from 156, dilution water may be added through valve 166 to the feed material in line 168. The consistency as measured at 156 is also preferably an input along line 170, to the control station 172.
The present invention is not specifically directed to the logic or algorithm associated with relating the pressure in line 158, the consistency as delivered in line 170, the power as sensed through line 174, and the total flow of the refiner output, to the quality or other desired characteristics of the refined fiber. Rather, the invention is directed to a secondary type of control, in that once the total flow and other conditions are specified, the gap width will be adjusted to be equal, within a predetermined tolerance, by adjustment of valves 184 and 180.
FIG. 5 shows another refiner embodiment 300, which for convenience, will be referred to as a converging conical refiner. The rotor 302 is in the shape of two symmetric frustroconical portions 304,306 connected near their larger diameter ends 308,310, with the bases of the smaller diameter ends 312,314 connected to shaft segments 316. The rotor 302 is situated within the casing shown generally at 318, for rotation about the horizontal axis of the shaft.
The refiner 300 is symmetric about the vertical plane 320 passing through the rotor, so that only one side thereof will be further described herein. Feed material enters the refiner through inlet 322, whereupon it is redirected at the smaller diameter portion of the rotor, into the conical refining zone or gap 324 between the rotating plate 326 carried by the conical surface 328 of the rotor, and the stator plate 330 which is rigidly supported by the casing at 332. Refined fiber also emerges from the refining gap 334 on the other conical portion of the rotor 302.
Opening 336 in the casing discharges the fiber emerging from gap 324, and opening 338 discharges the fiber emerging from gap 334. As in the previously-described embodiments, a divider 340 extends from the casing to a cylindrical portion at the apex 342 of the rotor, on the plane 320, for separating the two flow streams of refined fiber. Control valves 344,346 are provided in the respective discharge lines.
Those familiar with the present technology, can appreciate the ready adaptation of the control system shown in FIG. 3, for use with the refiner embodiment 10 shown in FIG. 1, and refiner embodiment 300 shown in FIG. 5.
The invention may be incorporated into yet another mechanical configuration, such as the diverging conical refiner 400 shown in FIG. 6. In this embodiment, a rotor 402 is supported by a rotatable shaft 416 within a casing 401. The rotor has the form of two frustoconical outer portions 407,412 connected at their minor diameters, on either end of a cylindrical center portion 403, about a plane of symmetry 409 passing through the central portion. The feed slurry is introduced along the plane of symmetry 409 through inlet conduit 410, and passes axially away from the plane of symmetry in each direction, toward the conical, outer portions. The conical portions of the rotor carry respective rotating refining plates 422,424, whereas stator plates 426,428 are supported by the casing, as by stator support rings 408.
The material flow is therefore in two opposite directions, away from the plane of symmetry 409, whereby the outflow from the first and second refining gaps 411,413 occurs at the major diameters of the outer portions 407, 412.
In the illustrated embodiment, the stator rings 408 provide fluid isolation between the inlet 410 and associated annulus 430, and the two discharge regions 415, at the major diameters of the rotor member. In this manner, isolation is maintained between the outflows emerging from the first refining gap 411 through a first discharge opening 417 in the casing, and the outflow emerging from the second refining gap 413 for discharge through a second discharge opening 419 in the casing. Valves 432,434 are provided as in the previously described embodiments.
The invention may also be implemented with a priority on equalizing the discharge flow from each of the refining gaps, in situations such as represented in FIG. 7. A system 500 comprising two (or more) refiners in series, such as 100 (see FIG. 1), or 400 (see FIG. 6) are fed from a single feedstream, but deliver discharge flows in two distinct lines leading to distinct feed inlets in a second refiner such as 10 (FIG. 1) or 300 (FIG. 5).
In this configuration, a main slurry feed line 158 introduces the feed to refiner 100, where the output of the two refining gaps emerge from the refiner at 140 and 142, respectively, for transfer downstream along lines 176,178. The material in line 176 passes through valve 180, and is introduced into refiner 10 at inlet 27, whereas the material in line 178 passes through 184 and is introduced into refiner 10 at inlet 26. In refiner 10, the material at inlet 27 and 26 is further refined in respective distinct refining zones, and discharged from the refiner along respective discharge lines 58,56. The discharged material passes respectively through valves 518 and 520 to the refined storage chest 179.
FIG. 7 also shows a simplified adaptation of the control system of FIG. 3, centered about the control station 502. Signals commensurate with the gap widths in refiner 100, are delivered over lines 504 to controller station 502, along with any other data that may be used in conventional control techniques. In addition, the respective flow rates in lines 176 and 178 are delivered along signal paths 506 to the controller station 502. In like fashion, signals commensurate with the refining gap widths and other relevant data from the refiner 100, are delivered along signal paths 508 to the control station 502, and the discharge flow rates in lines 58,56 are similarly delivered along data paths 510 to station 502. A level signal or the like is also transmitted from the storage chest 179, along data path 512, to station 502.
Control signals based on the data acquired along the foregoing data paths, are then delivered along paths 514 to valves 180 and 184, and along paths 516 to valves 518 and 520. As can be appreciated by the practitioners in this field, the system depicted in FIG. 7 requires, during steady state operation, that the total flow delivered to refiner 100 along main feedline 158, equal the total flow emerging from valves 518 and 520, which in turn should be commensurate with the maintenance of the desired level of material in the storage chest 179. Given this constraint, the system in accordance with the present invention, provides flexibility in optimizing performance by achieving substantially equal gap widths in one or both refiners, or substantially equal flow rates in each gap of one or both refiners, while satisfying the overall system total flow requirements.
It should also be appreciated that in another implementation of the invention, the data lines 506 and/or 510 can include measurements of pressure, rather than flow rate, in lines 176,178,58, and 56. In this embodiment, the control station 502 would, for example, maintain the relationship of valves 180 and 184, to maintain equal pressure in lines 176,178, upstream of the valves, i.e., thereby equalizing the discharge pressure of each refining gap associated with discharge openings 140,142, respectively. Such pressure equalization could be achieved in one or both of the refiners shown in the system of FIG. 7, or with respect to any of the individual refiners shown in FIG. 1,2,5, or 6. A control logic analogous to that shown in FIG. 4 could readily be implemented, to equalize the pressure in each discharge line, while maintaining the desired total flow.
The control schemes described above could be adapted by those skilled in this field, for use in a refiner having more than two refining zones. One such refiner is shown in U.S. Pat. No. 4,783,014, the disclosure of which is hereby incorporated by reference. The refiner has six refining zones, defined by three axially spaced apart rotating discs alternating with stator rings. The refiner disclosed in said patent, would of course be modified to include divider rings between each refining zone, and a separate discharge opening and associated valve, for each zone. Individual control of the flow in each refining zone, or the discharge pressure for each refining zone, could readily be implemented, whether or not the system includes the gap width adjustment aspect of the present invention. | In an apparatus (10,100,300,400) for refining a low consistency fibrous slurry, which includes a plurality of refining zones (38,40; 188,128; 324,334; 411,413) within a casing, the improvement comprises providing a unique discharge flow path from each refining zone to a respective unique discharge line (56,58; 130,142; 308,310; 411,413) out of the casing, and means (57,59; 141,143; 344,346; 432,434) for differentially adjusting the flow rate in each discharge line. In accordance with the preferred embodiment of the invention, a divider (42,132,340) is provided between the casing and the rotor member, thus dividing the discharge between the two refining gaps, into two separate flow streams. The first and second gaps are monitored in any conventional manner. Under operating conditions, the flow control valves are adjusted for combined flow from the refiner casing as required by the production demands. However, the relative positioning between the two valves is adjusted until the refining gap measurements show equal gaps (within a pre-established tolerance) in the two refining zones. | 3 |
BACKGROUND OF THE INVENTION
The present invention relates to apparatus for making use of water for health care.
Among the natural means of stimulating human blood circulation and of increasing physical resistance is, inter alia, the use of water. What this involves is applying water to the body in a varying pattern both by applying the water intermittently to individual parts of the body and thereby performing massage, and at the same time varying the temperature of the water.
To use water in this way an assistant is generally required such as are available in baths and spas for example. It would however be useful if water could be used in this way without outside help and above all if this were possible in the home.
However, ordinary domestic showers which have hand spray-nozzles fail to meet the requirements which then exist. Firstly the spray heads are designed more for sprinkling than for massaging and are therefore unsuitable and secondly hardly any user would be capable of using a hand spray-nozzle in such a way that water was applied systematically and effectively to all parts of the body. There is also the slight risk that water will get outside the shower when this is done.
In addition to showers of this nature there are also ones in which a number of nozzles is arranged along the walls. Leaving aside the facts that it is very expensive to equip a shower in this way ab initio and that it is virtually impossible so to fit it up afterwards, intermittent massage of individual parts of the body is not possible in this way.
It is here that the invention finds its place. It is an object of the invention to provide an apparatus for using water for health care which enables a user to apply water intermittently to individual parts of the body without outside help and to apply massage in so doing, and at the same time to vary the temperature of the water. The intention is also that the apparatus should be suitable for fitting to existing shower installations.
SUMMARY OF THE INVENTION
This and other objects are achieved in accordance with the proposal of the invention by an apparatus consisting of a guide strut to be attached vertically to a wall, a stand or the like, a slider which cooperates with the guide strut, a spray tube or the like connected to the slider which has a connector for a flexible water supply pipe, a drive element, preferably arranged inside the guide strut, which is responsibe for the up and down movement of the spray tube and which has a drive means and a switch which serves to reverse the direction of rotation of the drive means and which can be operated by two spaced engagement members.
The apparatus according to the invention is particularly easy to fit to a wall, especially in an existing shower, but can also be used in the open, etc., on a stand of its own. The slider is usefully fitted to the guide strut in such a way as to be secure against rotation. The spray tube may be of various shapes, e.g., U-shaped or straight and it is advantageous for it approximately to match the width of the human body. Water is fed in through a flexible water-supply pipe as in the case of a conventional hand spray-nozzle. Thus, in the simplest case, the water supply pipe may be detached from a hand spray-nozzle and connected, when required, to the apparatus according to the invention.
Widely differing types of drive are possible (e.g., hydraulic) but preferably it is electric and designed for low voltage. The switch and the actuators provide a continual and automatic switched change-over and thus for a continuous up and down movement by the spray tube.
In this way, the apparatus according to the invention allows water to be used or water massage to be given in the manner desirable for health care, i.e., provides for water to be applied intermittently to individual parts of the body with the additional possibility of varying the temperature of the water at the same time, without an assistant being required for this purpose. The water may be used in this way in existing shower installations in the home and also in the open.
In a further refinement of the concept of the invention, the drive element consists of a first return roller arranged at the upper end of the guide strut, and an endless cable or the like, the endless cable passing round the return rollers and being connected to the spray tube and preferably the second return roller being free running while the first return roller is connected to the drive means.
The particular advantage of this embodiment lies in the fact that the spray tube is moved in a simple and safe fashion.
Thus, no damage occurs even if the spray tube should be forcibly restrained or pulled back, since all that happens in this case is that the endless cable slips on the return rollers and afterwards resumes its proper movement.
To improve the transmission of power from the first return roller to the endless cable, the first return roller is provided with a friction covering and the second return roller is arranged in a mounting and its distance from the first return roller is adjustable.
In order that the range of action of the spray tube can be altered in a particularly simple fashion, in accordance with a further proposal the switch is arranged in the vicinity of the endless cable and an engagement member is designed to act as an abutment having a bore to receive the endless cable, a locking screw for clamping it to the endless cable, and longitudinal slots to provide guidance in the guide strut.
The apparatus according to the invention is particularly simple to fit up and maintain if, in accordance with a further proposal, a spindle is used as the drive element.
In order that the range of action of the spray tube can easily be altered, the switch has an actuating rod which extends along a line parallel to the guide strut and which carries engagement members, a further engagement member being mounted preferably on the slider and coming alternately into contact with the other engagement members.
In accordance with a further proposal, the spindle for moving the spray tube up and down is connected by a transmission means to a second spindle having a considerably finer thread which is arranged in the vicinity of the switch and which carries a threaded part which is moveable in the longitudinal direction to operate the switch.
A particularly compact design is possible if the spindle has at its upper end a section having a considerably finer thread which carries a threaded part which is moveable in the longitudinal direction to operate the switch.
The engagement members are usefully arranged on the threaded part and are adjustable in the longitudinal direction.
In accordance with another proposal, the switch has an actuating rod which extends along a line parallel to the second spindle or the more finely threaded section and which carries the engagement members and the threaded part has a further engagement member which makes contact alternately with the other engagement members.
Advantageously, at least one engagement member is adjustable on the actuating rod.
In a further refinement of the concept of the invention, the slider has a mounting in which the spray tube is held in such a way as to be displaceable in the direction of its longitudinal axis and in such a way that it can be turned to adjust the angle at which it is set.
BRIEF DESCRIPTION OF THE DRAWINGS
In order that the invention may be more clearly understood, reference will now be made to the accompanying drawings which show presently preferred embodiments thereof by way of example and in which:
FIG. 1 is a front view, partly cut away, of a first embodiment of apparatus,
FIG. 2 is a cross-section of this apparatus taken along line B--B of FIG. 1,
FIG. 3 is an enlarged section through the guide strut shown in FIG. 1, on line C--C,
FIG. 4 is a front view, partially cut away, of a second embodiment of apparatus,
FIG. 5 is a section through the subject of FIG. 4 on line D--D,
FIG. 6 is a front view, partly cut away, of a third embodiment, and
FIG. 7 is a front view, also partly cut away, of a further embodiment.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Referring now to the drawings, the apparatus shown in FIGS. 1 and 2 consists of a guide strut 1 which is fitted vertically to a wall 2 of a shower cabinet 3. Connected to the guide strut is an elongated spray tube 4 which is orientated transversely to the guide strut 1. By means of a connector 5 at one of its ends the spray tube 4 is connected to a flexible water-supply pipe 6. In operation, water emerges from the spray tube 4 in powerful jets directed in approximately the same direction through nozzles 7 which are arranged in a longitudinal line. The unconnected end of the spray tube 4 is also formed as a connector 5 but is closed off by a plug 8.
In its central region the spray tube 4 is held by a mounting 10 having a locking screw 11. The mounting 10 encloses the spray tube 4 and when the locking screw 11 is released it allows the spray tube 4 to be moved in the direction of its longitudinal axis and to be turned about its longitudinal axis to allow the angle at which its nozzles 7 are set to be adjusted. In addition, it is also possible for the spray tube 4 as a whole to be exchanged for another tube having larger or smaller nozzles or more or fewer nozzles, etc.
The guide strut 1 is a tube 1a containing a longitudinal slot 1b. In the longitudinal slot 1b, a slider 12a provided with guide slots is held so as to be sure secure against the rotation and is able to move up and down.
The slider 12a is connected on the one hand to the mounting 10 and on the other hand to an endless cable 15a which passes over a first return roller 16a at the upper end of the guide strut 1 and a second return roller 16b at the lower end of the guide strut 1. The first return roller 16a is located in a housing 17 which is arranged at the upper end of the guide strut 1 and which in the present case is shown without its front cover.
Whereas the second return roller 16b is free to rotate, the first return roller 16a has a drive means 18 in the form of an electric motor which is fed by a low-voltage battery 19 and which can be started by an on/off switch 20 and whose direction of rotation can be reversed by a switch 21 in the form of a polarity-changing switch. The first return roller 16a is provided with a friction covering to enable it better to apply traction to the endless cable 16a.
The drive means 18, together with low-voltage battery 19, the on/off switch 20 and the switch 21 are also arranged in the housing 17, the on/off switch 20 being accessible or operable from outside. The switch 21 has an arm 22 which is provided with a bore through which the endless cable 15a is provided with two engagement members 23 and 23a which are unable to pass through the bore and which instead move the arm 22, as a result of which the direction of rotation is reversed. In the present embodiment the engagement member 23 is a knot in the endless cable 15a.
As can more clearly be seen in FIG. 3, the engagement member 23a is in the form of an adjustable abutment having a bore to receive the endless cable 15a, a locking screw to clamp it to the endless cable 15a, and longitudinal slots 24 to guide it in the guide strut 1, that is to say in the longitudinal slot 1b of the latter. By means of this engagement member, it is possible without difficulty to alter the range over which the spray tube 4 moves continuously up and down.
It can also be seen from FIG. 1 that the second return roller 16b is arranged in a U-shaped mounting 25. This mounting is held in a blanking plate 27 at the lower end of the guide strut 1 by means of a threaded shank 26. The threaded shank 26 passes through a bore 28 in the blanking plate 27 and carries a nut 29. Between the nut 29 and the blanking plate 27 is arranged a compression spring 30. The bore 28 in the blanking plate 27 is sufficiently large for the threaded shank 26 to be able to move freely in the longitudinal direction of the guide strut 1. The compression spring 30 however attempts to press the threaded shank 26 outwards, which places the endless cable 15a under tensile stress. The tensile stress can easily be altered by adjusting the nut 29.
FIGS. 4 and 5 show a structure which is largely similar but in this case the up and down movement of the spray tube 4 is brought about by means of a spindle 31 which is arranged in the guide strut 1 and which cooperates with a slider 12b which is guided inside the guide strut 1 in such a way as to be secure against rotation and which has a bore 32 having an internal thread matched to the external thread on the spindle 31. The slider 12b is connected to the mounting 10 and with each rotation of the spindle 31 is moved further up or down. In the vicinity of the switch 21 is arranged a second spindle 33 which is sufficiently small to be completely accommodated in the housing 17. The second spindle 33 carries a threaded part 34 which is moveable in the longitudinal direction and it is connected by a transmission device 35 to the first spindle 31. The transmission device 35 is so designed that the second spindle 33 turns more slowly than the first spindle 31. In addition, the second spindle 33 has a finer thread than the first spindle 31 and as a result the threaded part 34 moves for considerably shorter distances than the spray tube 4.
The threaded part 34 is provided with engagement members 23b which are able to operate the switch 21 via its arm 22. The engagement members 23b are adjustable in the longitudinal direction of the second spindle 23, the members passing through the housing 17 and being accessible from the exterior. In this way the range of action of the spray tube is once again easily able to be altered both as regards the distance from one point of reversal to the other and also as regards height.
The drive element in FIG. 6 for the spray tube is once again an endless cable 15a. In contrast to FIG. 1, in the present case the switch 21 has an actuating rod 36 which extends along a line parallel to the guide strut 1 and which is loosely mounted. The actuating rod 36 carries two adjustable engagement members 23c while the slider 12a has one further engagement member 23d.
When the drive means 18 is switched on, the engagement member 23d comes alternately into contact with the engagement members 23c, as a result of which there is a continual reversal of the direction of rotation of the drive means. This method of control is not dependant on the nature of the drive element. The drive element could equally well be a spindle or a piston and cylinder arrangement or the like.
FIG. 7 shows a further preferred embodiment of the invention. In this case, the spindle 31 extends directly into a threaded section 37 having a considerably finer thread and is connected to the drive means 18. The threaded section 37 carries a threaded part 34 carrying an engagement member 23d.
The threaded part 34 moves simultaneously with the spray tube 4 but for a considerably shorter distance. The switch 21 once again has an actuating rod 36 but in this case the rod extends only along the threaded section 37. On the actuating rod 36 are once again arranged two engagement members 23c. These pass through the housing 17 and are adjustable. By means of them the range over which the spray tube 4 is to perform a continuous up and down movement may be adjusted in a particularly simple fashion. | This invention relates to apparatus for making use of water for health care. A guide strut is arranged for vertical attachment to a support means which may be a wall or a stand device and a slider cooperates with this guide strut; a spray tube is connected to the slider and a connector is provided on the spray tube to accept a flexible water-supply pipe. There is a drive element associated with the guide strut which is arranged to effect the up and down movement of the spray tube and is fitted with a drive means and a switch; the switch serves to reverse the direction of rotation of the drive means and is arranged to be actuated by two spaced engagement members. | 4 |
BACKGROUND
[0001] In hydrocarbon exploration and energy industries, estimation of subterranean hydrocarbon reservoirs is accomplished using various techniques for measuring formation properties. Some techniques involve coring, in which rock cores from a formation are taken by drilling into a formation using a drill string that includes a core bit. During a coring operation, a rock core in the drill string is retrieved by retrieving the core via the drill string or wireline, which is referred to as “tripping.” During tripping, damage to the core can occur due to decompression in the borehole, which can change various properties of the rock in the core and thus compromise results of analysis of the core at the surface. Tripping schedules should be planned that minimize core damage while allowing retrieval of the core within an acceptable time frame.
SUMMARY
[0002] An embodiment of a method for removing a core sample from a borehole includes: taking the core sample within the borehole with a sampling tool; generating a model of the core sample, the model based on data representing properties of the core sample; defining a plurality of proposed tripping schedules; applying, by a processor, the plurality of proposed tripping schedules to the model, and estimating a core parameter for each of the plurality of proposed tripping schedules; comparing the core parameter to a criteria; and selecting a suitable tripping schedule based on the comparison.
[0003] An embodiment of a system for removing a formation core sample from a borehole includes: a carrier configured to be disposed in a borehole in an earth formation, the carrier configured to receive a core sample of the formation, and a processor configured to provide a suitable tripping schedule. The processor is configured to perform: generating a model of the core sample, the model based on data representing properties of the core sample; defining a plurality of proposed tripping schedules; applying the plurality of proposed tripping schedules to the model, and estimating a core parameter for each of the plurality of proposed tripping schedules; comparing the core parameter to a criteria; and selecting the suitable tripping schedule based on the comparison.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] The following descriptions should not be considered limiting in any way. With reference to the accompanying drawings, like elements are numbered alike:
[0005] FIG. 1 is a side cross-sectional view of an embodiment of a drilling and/or geosteering system;
[0006] FIG. 2 is a flow chart providing an exemplary method of evaluating tripping schedules and determining a suitable tripping schedule;
[0007] FIG. 3 depicts an embodiment of a mathematical model of a formation core sample;
[0008] FIG. 4 depicts an exemplary pore pressure distribution in the model of FIG. 3 ;
[0009] FIG. 5 depicts exemplary proposed tripping schedules selected for application to a mathematical model of a formation core sample;
[0010] FIG. 6 depicts a proposed tripping schedule of FIG. 5 and core parameters resulting from application of the proposed tripping schedule to the model;
[0011] FIG. 7 depicts a proposed tripping schedule of FIG. 5 and core parameters resulting from application of the proposed tripping schedule to the model;
[0012] FIG. 8 depicts a proposed tripping schedule of FIG. 5 and core parameters resulting from application of the proposed tripping schedule to the model;
[0013] FIG. 9 depicts a revised tripping schedule generated based on application of a proposed tripping schedule of FIG. 5 to the model; and
[0014] FIG. 10 depicts a revised tripping schedule generated based on application of a proposed tripping schedule of FIG. 5 to the model.
DETAILED DESCRIPTION
[0015] The systems and methods described herein provide for modeling of downhole parameters such as pore pressure to predict or estimate an optimum or suitable tripping schedule that minimizes core damage from decompression while tripping a formation core sample out of a borehole within a selected time period. An embodiment of a method includes generating a mathematical model of a formation core sample based on geometric properties of the core and core material properties such as permeability and fluid characteristics. Selected tripping schedules may be input to the model to generate predicted parameter values or curves that can be associated with potential core damage. An exemplary method includes iteratively applying multiple proposed tripping schedules to the model. A “suitable” tripping schedule is calculated by selecting one of the applied tripping schedules or iteratively adjusting one or more proposed tripping schedules until a tripping schedule having acceptable time and core damage criteria is found.
[0016] In one embodiment, the method and an associated algorithm provides an automated mechanism that derives at an optimal tripping schedule without user interference. The algorithm, in one embodiment, can be run in two modes. In a first mode, e.g., a batch mode, a plurality of proposed tripping schedules are input to the model for which a sample of model parameters is chosen, and an optimum or suitable tripping schedule is selected from the proposed tripping schedules based on results of the executed model for each proposed tripping schedule. In a second mode, also referred to as a “smart” mode, the algorithm tunes or adjusts proposed tripping schedules or subsequently inputted tripping schedules based on the output from previous model executions.
[0017] In one embodiment, maximum pore pressure differences within the core are calculated at various depths and/or times based on the model for each proposed tripping schedule. The maximum pore pressure differences are compared to pore pressure difference criteria associated with the tensile rock strength of the core material to predict core damage due to gas expansion or decompression. A tripping schedule is identified and/or calculated that is best suited to minimize core damage.
[0018] The systems and methods described herein provide for the ability to estimate whether core damage from decompression might occur for given material parameters and tripping schedules. Such systems and methods also provide for automated quantitative evaluation of tripping schedules to generate a schedule that optimizes the trade-offs between key parameters, such as permeability, tripping speed and/or duration, and tensile rock strength.
[0019] Referring to FIG. 1 , an exemplary embodiment of a downhole drilling system 10 disposed in a borehole 12 is shown. A drill string 14 is disposed in the borehole 12 , which penetrates at least one earth formation 16 . Although the borehole 12 is shown in FIG. 1 to be of constant diameter, the borehole is not so limited. For example, the borehole 12 may be of varying diameter and/or direction (e.g., azimuth and inclination). The drill string 14 is made from, for example, a pipe or multiple pipe sections. The system 10 and/or the drill string 14 include a drilling assembly 18 . In one embodiment, the drilling assembly is configured as a coring assembly or tool. Various measurement tools may also be incorporated into the system 10 to affect measurement regimes such as wireline measurement applications or logging-while-drilling (LWD) applications.
[0020] The drilling assembly 18 , which may be configured as a bottomhole assembly (BHA), includes a drill bit 20 and is configured to be conveyed into the borehole 12 from a drilling rig 22 . In one embodiment, the drilling assembly is a coring assembly configured to obtain core samples of the formation 16 . The drill bit 20 in this embodiment is a coring bit incorporated as part of a coring or sampling tool. An exemplary tool includes a coring bit attached to a drill collar having an inner bore configured to receive and retain the core sample.
[0021] In one embodiment, one or more downhole components, such as the drill string 14 and the drilling assembly 18 , include sensor devices 24 configured to measure various parameters of the formation and/or borehole. For example, one or more parameter sensors (or sensor assemblies such as LWD subs) are configured for formation evaluation measurements relating to the formation, borehole, geophysical characteristics and/or borehole fluids. These sensors may include formation evaluation sensors (e.g., resistivity, dielectric constant, water saturation, porosity, density and permeability), sensors for measuring geophysical parameters (e.g., acoustic velocity and acoustic travel time), and sensors for measuring borehole fluid parameters (e.g., viscosity, density, clarity, rheology, pH level, and gas, oil and water contents).
[0022] The sensor devices 24 , drilling assembly 18 and other downhole components may be included in or embodied as a BHA, drill string component or other suitable carrier. A “carrier” as described herein means any device, device component, combination of devices, media and/or member that may be used to convey, house, support or otherwise facilitate the use of another device, device component, combination of devices, media and/or member. Exemplary non-limiting carriers include drill strings of the coiled tubing type, of the jointed pipe type and any combination or portion thereof. Other carrier examples include casing pipes, wirelines, wireline sondes, slickline sondes, drop shots, downhole subs, bottom-hole assemblies, and drill strings.
[0023] In one embodiment, the drilling assembly 18 and sensor devices 24 are configured to communicate with one or more processors, such as a downhole electronics unit 26 and/or a surface processing unit 28 . The processor(s) may receive data and communication signals from the downhole components and/or transmit control signals to the components. Signals and data may be transmitted via any suitable transmission device or system, such as a cable 30 . Other techniques used to transmit signals and data include wired pipe, electric and/or fiber optic connections, mud pulse, electromagnetic and acoustic telemetry.
[0024] The processor or processors, in one embodiment, are configured to receive data and generate information such as a mathematical model for prediction of downhole parameters and conditions. For example, the processor is configured to receive downhole data as well as additional data (e.g., from a user or database) such as geometric data of borehole components. The processor may be configured to perform functions such as providing prediction or modeling information, controlling the drilling assembly 18 , transmitting and receiving data and monitoring the drilling assembly 18 and the drill string 14 . The surface processing unit 28 , the sensor devices 24 and/or other components may also include components as necessary to provide for storing and/or processing data collected from various sensors therein. For example, the surface processing unit 28 includes a processor 32 , a data storage device (or a computer-readable medium) 34 for storing, data, models and/or computer programs or software 36 .
[0025] Although the processors described herein are shown in communication with downhole components, they are not so limited. For example, a processor can be embodied as an independent computer or other processing device that can receive input data such as model parameters, measurement information and proposed tripping schedules.
[0026] Generally, some of the teachings herein are reduced to an algorithm that is stored on machine-readable media. The algorithm is implemented by a computer or processor such as the surface processing unit 28 and provides operators with desired output.
[0027] In one embodiment, a processor utilizes a quantitative (mathematical and/or numerical) method that models a formation sample core tripping out of a borehole as a permeable, elastic solid with an initial pore pressure and stress distribution, to which variable external pressures and/or loads are applied based on material parameters of the core and inputted and/or generated tripping schedules.
[0028] In one embodiment, the surface processing unit 28 or other processing device is configured to generate a model that simulates potential core damage based on inputted tripping schedules. The model may be used to estimate or select an optimum or suitable tripping schedule. A “suitable tripping schedule,” in one embodiment, is a schedule that results in removal of core samples within an acceptable time frame while reducing potential core damage to an acceptable level or otherwise satisfying core damage criteria. In addition to simulating potential damage, the processing device may be configured to analyze inputted tripping schedules and select or calculate an optimum or suitable tripping schedule.
[0029] In one embodiment, the model is used to compute the external pore pressure and stress history based on proposed tripping schedules, which in turn is applied as external loads and boundary conditions. The method computes equilibration pore pressures and stresses at different points in time based on inputted tripping schedules, and predicts pore pressure differences. These are used to evaluate a rock strength criterion (e.g., but not limited to tensile rock strength) to predict potential core damage.
[0030] In one embodiment, the processing device uses an algorithm that automates an iterative process of evaluating proposed tripping schedules. For example, the algorithm applies a plurality of proposed tripping schedules (potentially a large number of tripping schedules) to predict a pool of modeled core parameters, from which the algorithm can select the optimum or suitable tripping schedule. The algorithm may further include the ability to alter proposed tripping schedules in order to narrow in on the suitable schedule.
[0031] FIG. 2 illustrates a method 40 for evaluating tripping schedules and determining one or more optimum or suitable tripping schedules. The method provides a quantitative prediction of a tripping schedule that minimizes damage from core decompression while tripping out of a bore hole. The method 40 includes one or more of stages 41 - 45 described herein, at least portions of which may be performed by a processor (e.g., the surface processing unit 28 ). In one embodiment, the method includes the execution of all of stages 41 - 45 in the order described. However, certain stages 41 - 45 may be omitted, stages may be added, or the order of the stages changed.
[0032] Although the systems and methods described herein relate to drill string coring, they are not so limited. For example, the systems and methods may apply to wireline coring (e.g., the coring tool of system 10 is a wireline coring/core removal tool).
[0033] In one embodiment, the method is performed as specified by an algorithm that allows a processor (e.g., the surface processing unit 28 ) to automatically calculate an optimum or suitable tripping schedule. The processor as described herein may be a single processor or multiple processors (e.g., a network). The algorithm output may be a single schedule or a plurality of schedules that satisfy different criteria (e.g., time or damage).
[0034] The method can be used iteratively to obtain a suitable tripping schedule. The suitable tripping schedule may be one that minimizes or avoids predicted core damage while maintaining the total tripping time to within a desired limit. Short tripping times are desired as they provide economic benefits, e.g., save time and money.
[0035] In the first stage 41 , a mathematical model of a formation sample core (also referred to simply as a “core”) is constructed. The model is a quantitative analytical or numerical model of a poro-elastic core that can be subjected to varying external boundary conditions and pressure loads.
[0036] Various properties of the core are selected or inputted. As described herein, “properties” of the core include any data or information used to construct the model. Such properties include, for example, geometric properties and material parameter data providing information relative to formation characteristics such as formation rock properties, other formation material properties and properties of fluid in the formation.
[0037] Geometric data related to the drill string and the core is input to generate representations of the geometry of the core. Exemplary geometric parameters include length, diameter and depth. In one embodiment, the modeled core is assumed to have a cylindrical shape, having a diameter that is much smaller than its height, although any shape could be used.
[0038] An exemplary model is generated using the finite element method. In one embodiment, multiple elements are generated from the geometric data that correspond to the shape or geometry of different portions of the core geometry. In one embodiment, the core or a portion thereof is modeled as a three-dimensional model using finite three dimensional elements.
[0039] The model is not limited to the embodiments described herein, as any mathematical model that permits prediction of pressure conditions in a simulated core may be used. In one embodiment, the model may be a mathematical/analytical model instead of a numerical model. In other embodiments, a simplified numerical model may be used, such as a two-dimensional or one-dimensional model. For example, the model may be a simplified one-dimensional diffusion model that simulates a central profile along the core's radius. Such a simplified model may be desirable as it can be solved faster, thereby allowing for a larger number of iterations or a quicker result.
[0040] Material parameters are also estimated or selected for the core. The material parameters may be based on measurements taken downhole in the current borehole in which the core is to be removed, taken from previous measurements or otherwise assumed or estimated based on knowledge of the formation. For example, the system 10 may be used to take various measurements to determine formation parameters such as permeability that can be used to generate the model.
[0041] In one embodiment, the material parameters include fluid parameters and/or formation rock parameters. Exemplary parameters include permeability, porosity, fluid density and viscosity, and rock strength.
[0042] An exemplary model 50 of a core is shown in FIGS. 3 and 4 . The model 50 is an axisymmetric finite-element model of a core that contains a pore fluid. As shown in FIG. 3 , the model is symmetric about a symmetry axis 52 corresponding to a central axis of a coring tool. The model is subjected to boundary conditions 54 such as stress boundary conditions based on formation pore pressure and stress from the mud column.
[0043] FIG. 4 shows the upper part of an exemplary pore pressure distribution in the core, calculated by the model 50 after tripping. As shown, the pore pressure in a mid-horizontal region of the core decreases radially from the center of the core toward the boundaries of the core. In this example, the pore pressure is color coded from red (indicating higher values) to blue (indicating lower values).
[0044] In the second stage 42 , tripping schedules are defined. Tripping schedules may be defined by receiving tripping schedules from a user or by generating the tripping schedules by the processor. In one embodiment, one or more proposed tripping schedules are input to the algorithm by a user. Each tripping schedule may be a linear schedule or a more complex schedule.
[0045] In one embodiment, each tripping schedule is defined by tripping velocity (or scalar equivalent being the speed) as a function of depth. For example, each tripping schedule is specified by distinct points of depth and velocity pairs. The schedule can be specified directly or constructed, e.g., by linearly interpolating between a small number of depth/velocity points or by assigning constant tripping velocities for certain depth ranges. The velocity information may be used with depth differentials to obtain tripping times, e.g., the time duration of portions of the tripping schedule and/or the entire tripping time.
[0046] In the third stage 43 , initial conditions are set for the model. For example, initial values for external loads (e.g., stress) and pore-fluid pressure on the core are assigned and applied as boundary conditions to obtain an initial pore pressure distribution. The external stress and pore pressure values may be based on actual measurements, known properties of the formation and borehole, and/or depth information.
[0047] In one embodiment, the external stress and pore pressure are based on the mud weight column at the starting depth of the core, i.e., the depth of the core prior to tripping. For example, the in-situ pore pressure and the in-situ stress on the core at each depth are considered to be equal to the hydrostatic burden of drilling fluid in a borehole at that depth, given by (mud density)*g*(depth), where g is the acceleration due to gravity.
[0048] In one embodiment, a pressure amplitude is calculated for each depth. The pressure amplitude may be an amplitude of the pore pressure at a selected location of the model or the model boundary. For example, the pressure amplitude is the external pore pressure at a selected location on the core.
[0049] In the fourth stage 44 , each proposed tripping schedule is applied as an input to the model to generate core parameter values as a function of time and/or depth. For each proposed tripping schedule, the external pore pressure and stress are set as boundary conditions based on the depth of elements of the simulated core during the proposed tripping schedule.
[0050] The proposed tripping schedule may be specified by distinct points or increments of depth and tripping velocity. The pore pressure distribution in the core (or other pore pressure value, such as maximum pore pressure) is calculated at each depth point in the tripping schedule based on the model. For example, as the tripping schedule proceeds from the starting depth toward the surface, at each depth point or increment, the model is subjected to successively decreasing external pressure (i.e., successively decreasing external pore-pressure and stress boundary conditions). The model incrementally adjusts the pore pressure and the stress inside the core in response to the changing boundary conditions. As a result, core parameter values in the core at each tripping schedule increment are generated. The core parameter values may be output or displayed to a user as, e.g., a core parameter curve as a function of depth or time.
[0051] In the fifth stage 45 , each tripping schedule is analyzed to determine whether core damage could occur and to find a tripping schedule that minimizes core damage. At every increment or data point of the tripping schedule, the quantitative model is used to predict whether core damage from decompression might occur, e.g. by using information from the pore-pressure variable and a rock strength criterion (e.g., tensile rock strength).
[0052] The core parameter values calculated for each tripping schedule are compared to selected criteria related to potential core damage, time and/or other considerations. The time criteria may include the duration of the tripping process (e.g., the entire process or a portion thereof). Core damage criteria are related to potential core damage during tripping and/or factors that may affect the quality of the core sample. Core damage criteria may include values of any suitable properties of the core, formation and/or borehole during tripping. Such core damage criteria includes, for example, property values relating to stress, temperature, pressure, vibration, deformation and others, as well as the rate of change of such properties.
[0053] Using one or more of the criteria, a suitable tripping schedule is selected that reduces or minimizes core damage while also maximizes the overall speed of removal. The suitable tripping schedule is not so limited, as it may be selected to satisfy any selected criteria, e.g., quality, time and economic criteria.
[0054] In one embodiment, the parameter values are compared to core damage criteria at every tripping schedule point or increment to determine whether and/or how much core damage is predicted to occur at each time. The core damage criteria may include threshold parameter values associated with potential damage (or an unacceptable degree of damage). Other criteria include, for example, a duration of the tripping schedule during which core parameter values exceed a threshold and a number of data points for which core parameters values exceed a threshold. For example, the pore pressure differential calculated for each increment is compared to a selected threshold or pressure differential range associated with the tensile rock strength of the core.
[0055] In one embodiment, the proposed tripping schedule that predicts the least amount of core damage and/or meets the selected criteria is selected as the optimum or suitable tripping schedule. In one embodiment, after applying the proposed tripping schedules to the model, one or more of the proposed tripping schedules are iteratively adjusted and applied to the model until a proposed tripping schedule is considered suitable, e.g., meets core damage criteria.
[0056] Although the method 40 is described in conjunction with material parameters each having a single value, it is not so limited. For example, the method can include applying the proposed tripping schedules to multiple models of the core, each of the models having a different value for one or more material parameters selected from a range of values. The resultant core parameter values can be generated and/or displayed with an uncertainty range based on the range of material parameter values. In addition, proposed tripping schedules, revised tripping schedules and/or suitable or optimum tripping schedules can be generated and/or displayed with an uncertainty range based on the range of material parameters.
[0057] FIGS. 5-10 illustrate an example of the method 40 , which is performed by a processor. In this example, the method includes constructing an axisymmetric finite-element model of a core, such as the model 50 . The geometric parameters and all necessary material parameters are known or estimated. The geometric parameters of the core in this model are a core diameter of four inches and a core length of one meter. The depth of the core (i.e., the starting depth of proposed tripping schedules) is about 3,000 meters.
[0058] The material parameters selected for the model in this example are shown in the following table (Table 1). All non-scalar material parameters are assumed isotropic.
[0000]
TABLE 1
Material properties
Value
Permeability
9.869 × 10 −21 m 2 -9.869 × 10 −19 m 2
Fluid dynamic viscosity
3.6 × l0 −7 m 2 /s
Fluid specific weight
10 4 N/m 3
Hydraulic conductivity (derived)
2.689 × 10 −13 m/s-2.689 × 10 −11 m/s
Young's modulus
9 GPa
Poisson's ratio
0.2
Density
2 × l0 3 kg/m 3
Porosity (void ratio)
0.15
Drilling fluid density
1.6 × l0 3 kg/m 3
Fluid bulk modulus
1 GPa
Rock bulk modulus
5 GPa
Tensile rock strength
3 MPa
[0059] Although most material parameters shown above have a single value, the method is not so limited. In one embodiment, multiple models are generated, each having a different material parameter value, and proposed tripping schedules are applied to each model. The output of the method may include optimum or suitable tripping schedules for each model and/or an optimum or suitable tripping schedule having an uncertainty range based on the range of material parameter values. For example, the proposed tripping schedules are applied to models having different values for permeability (e.g., permeability values of 0.0001, 0.001 and 0.01 mDarcy).
[0060] FIG. 5 shows exemplary proposed tripping schedules selected for application to the model. The tripping schedules are displayed as tripping speed as a function of depth. A first proposed tripping schedule 60 prescribes a constant tripping speed, and is described as a “flat” schedule. A second proposed tripping schedule 62 is a “step” schedule prescribing three constant tripping speeds, and a third proposed tripping schedule 64 is a “smooth” schedule that prescribes a more gradually decreasing tripping speed relative to depth.
[0061] The tripping speed and depth is used to correlate each depth with a time value, and an amplitude of pressure on the core is calculated at each depth of the core. In this example, the pressure amplitude is calculated based on the mud weight at each depth. Pressure amplitude curves 66 , 68 and 70 are calculated for the flat schedule 60 , the step schedule 62 and the smooth schedule 64 respectively. The pressure amplitude at each time is used to calculate the external boundary condition and load on the model at the corresponding tripping schedule increment.
[0062] For each proposed tripping schedule, pore pressure evolution in the core is calculated using the model. The minimum and maximum pore pressure in the core is calculated, and a pressure differential is calculated therefrom. The processor stores, among other information, the minimum and maximum pore pressure at each time increment.
[0063] FIGS. 6-8 illustrate the resultant pore pressure parameter values for each proposed tripping schedule as curves representing the maximum and minimum pore pressure in the core (e.g., maximum at center and minimum at or near edge or boundary) and the pore pressure differential. The resultant values for the proposed tripping scheduled may be stored and/or displayed to a user.
[0064] Each proposed tripping schedule is compared to selected damage criteria to determine whether any meet the criteria. In this example, the calculated pore pressure parameters are compared to threshold values indicative of core damage, to determine whether the proposed tripping schedules potentially cause core damage.
[0065] In the present example, the calculated differential pressure values are compared to a differential pressure threshold of about 3 MPa, which is associated with an unacceptable level of core damage.
[0066] As shown in FIG. 6 , the proposed flat schedule 60 results in a maximum pore pressure curve 72 , a minimum pore pressure curve 74 and a differential pressure curve 76 . It is evident that the proposed flat schedule 60 results in a differential pressure that exceeds a threshold value 78 associated with the tensile rock strength over most of the duration of the proposed tripping.
[0067] As shown in FIG. 7 , the proposed step schedule 62 results in a maximum pore pressure curve 80 , a minimum pore pressure curve 82 and a differential pressure curve 84 . As shown in FIG. 8 , the proposed smooth schedule 64 results in a maximum pore pressure curve 86 , a minimum pore pressure curve 88 and a differential pressure curve 90 . Both the proposed step schedule and smooth schedule exceed the threshold over portions thereof.
[0068] As none of the proposed tripping schedule meet the core damage criteria, the processor proceeds to analyze additional proposed schedules if provided until a schedule that meets the criteria is found. Alternatively, if none is found, the processor may present to a user one or more of the proposed tripping schedules that are predicted to result in the lowest damage. In one embodiment, the results of the analysis for one or more of the tripping schedules is displayed to a user, who may input additional proposed tripping schedules.
[0069] In one embodiment, shown in FIGS. 9-10 , the processor iteratively adjusts one or more of the proposed tripping schedules until an acceptable tripping schedule is found. For example, as shown in FIG. 9 , the flat schedule is adjusted to produce a first revised schedule 92 , which is associated with a pressure amplitude curve 94 . Application of this schedule to the model produces a maximum pore pressure curve 96 , a minimum pore pressure curve 98 and a pore pressure differential curve 100 . As shown in FIG. 9 , the differential pore pressure is maintained at about the threshold level.
[0070] Referring to FIG. 10 , the processor further adjusts the revised schedule 92 to produce a second revised schedule 102 having an associated amplitude curve 104 . Application of this schedule to the model produces a maximum pore pressure curve 106 , a minimum pore pressure curve 108 and a pore pressure differential curve 110 . This revised schedule may be selected as the optimum or suitable schedule, or further revised (e.g., to further reduce the total tripping time while maintaining the differential pore pressure below threshold levels).
[0071] In addition to effects of pressure release while tripping out, additional mechanisms may affect core integrity and lead to core damage. Such mechanism include the effect of a mud cake, in-situ stress orientations, external stress release during drill out, temperature reduction and exposure to non-native fluids. The method described herein may be used in conjunction with other techniques or methods that account for such mechanisms in evaluating tripping schedules and ensuring acceptable or maximum core integrity.
[0072] The systems and methods described herein provide various advantages over prior art techniques. For example, the systems and methods allow for automated selection and/or generation of a tripping schedule for removal of a formation core sample that results in minimal or reduced core damage without requiring user intervention. The systems and methods described herein help to ensure that core samples can be removed as quickly as possible without breaking or otherwise being significantly damaged.
[0073] In support of the teachings herein, various analyses and/or analytical components may be used, including digital and/or analog systems. The system may have components such as a processor, storage media, memory, input, output, communications link (wired, wireless, pulsed mud, optical or other), user interfaces, software programs, signal processors (digital or analog) and other such components (such as resistors, capacitors, inductors and others) to provide for operation and analyses of the apparatus and methods disclosed herein in any of several manners well-appreciated in the art. It is considered that these teachings may be, but need not be, implemented in conjunction with a set of computer executable instructions stored on a computer readable medium, including memory (ROMs, RAMs), optical (CD-ROMs), or magnetic (disks, hard drives), or any other type that when executed causes a computer to implement the method of the present invention. These instructions may provide for equipment operation, control, data collection and analysis and other functions deemed relevant by a system designer, owner, user or other such personnel, in addition to the functions described in this disclosure.
[0074] One skilled in the art will recognize that the various components or technologies may provide certain necessary or beneficial functionality or features. Accordingly, these functions and features as may be needed in support of the appended claims and variations thereof, are recognized as being inherently included as a part of the teachings herein and a part of the invention disclosed.
[0075] While the invention has been described with reference to exemplary embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications will be appreciated by those skilled in the art to adapt a particular instrument, 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. | A method for removing a core sample from a borehole includes: taking the core sample within the borehole with a sampling tool; generating a model of the core sample, the model based on data representing properties of the core sample; defining a plurality of proposed tripping schedules; applying, by a processor, the plurality of proposed tripping schedules to the model, and estimating a core parameter for each of the plurality of proposed tripping schedules; comparing the core parameter to a criteria; and selecting a suitable tripping schedule based on the comparison. | 4 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] The present application is a continuation-in-part of U.S. patent application Ser. No. 12/316,954, filed Dec. 16, 2008, which is a continuation-in-part of U.S. patent application Ser. No. 11/522,159 filed Sep. 18, 2006; the entire contents of these previous applications are fully incorporated herein by reference.
RELATED FIELD OF THE INVENTION
[0002] The present disclosure describes a method and system for a user friendly, Internet based estate planning and planned giving tool available for a wide area network (Internet) for, e.g., non-profit organizations and their donors (more generally contributors herein), wherein the method and system may be driven at least partially by data indicative of a predetermined perspective consistent with the organization's values and operating procedures.
BACKGROUND
[0003] There is a need for method and system for managing the effort of soliciting and obtaining contributions for philanthropic organizations or entities, and additionally for easing the effort required by contributors. The present disclosure describes such a method and system.
SUMMARY OF THE INVENTION
[0004] The present disclosure is generally directed to a user friendly web based system and method which provides entities (particularly, non-profit entities) and their contributors (candidate or actual) therefor with presentations, materials, strategies, and other resources for allowing such entities and candidate contributors:
(a) To better understand and appreciate philanthropic endeavors, processes and techniques regarding philanthropic contributions (e.g., donations) and the reasons therefor; (b) To provide educational materials and presentations regarding planned/scheduled contributions, tax matters related to contributions, wherein such materials can be generally applicable to a wide range of circumstance, as well as customized to a particular entity and/or contributor's circumstances; (c) To provide software tools for assisting in, e.g., determining financial projections for contributors which may include modeling a contributor's financial circumstances through time, and/or providing representations of tangible physical objects that such an entity or a contributor may or may not be able to purchase or obtain given the contribution(s) made or not made; (d) To provide a web based estate plan organizer wherein contributors can confidentially input personal, financial information and receive advice regarding various estate planning ideas and/or scenarios; (e) To provide contacts with professionals familiar with philanthropic matters; and in particular, provide access to and/or referrals from one or more social/professional networks of individuals and organizations to assist the (potential) contributors in their estate planning matters, wherein reduced fees may be charged to such contributors. In one embodiment, a network of attorneys may be provided that share, affirm or otherwise are well versed in issues related to philanthropic giving; and (f) To provide any or all of the above information and materials in a manner that is consistent with a predetermined perspective of the (potential) contributor's values and/or with a predetermined perspective of the values and operating procedures of an organization or entity utilizing the method and system disclosed herein to solicit donations or contributions from (potential) contributors.
[0011] In one embodiment of the method and system of the present disclosure automated e-mail messages are provided to potential or actual donors e.g., who have requested information) for a plurality of organizations or entities contracting or otherwise providing access to the philanthropic services disclosed herein. For each such organization or entity, the e-mail messages generated therefor may include graphics, logos and other information for identifying the organization or entity as well as hyperlinks to Internet services and information provided by an embodiment of the presently disclosed method and system. In particular, such e-mail messages provide potential or actual donors (collectively also identified as “contributors” herein) with information promoting seminars related to philanthropic giving, current tax advantages for giving opportunities and charitable estate planning. Moreover, such emails may be substantially automatically generated for combining, e.g., information provided by the organization or entity (e.g., specifically for a particular collection of emails to be transmitted on a specific date), information identifying the organization or entity (logos, etc.), philanthropic information and presentations customized to the organization or entity, and access to software tools for modeling and/or determining financial or life style projections related to philanthropic giving.
[0012] In one embodiment of the method and system of the present disclosure network seminars (e.g., webinars) are provided to inform participants about various estate planning and charitable giving matters. Participants of instances of such seminars may be provided with authorization information providing access to such seminars. Such seminars may provide information to assist contributors in their estate planning needs. Such seminars may be presented on one or more communication networks, e.g., the Internet, a phone network, a wireless network, or a combination of networks wherein presentation media from various networks are combined or synchronized to provide enhanced user (contributor) experiences. Accordingly, such seminars (more generally, “presentations”) may be tailored to the presentation capabilities of each presentation participant. Thus, participants may be provided with a version of a presentation that utilizes only audio communication, while other participants may be provided with a version of the presentation that utilizes audio plus a low (or erratic) visual presentation, e.g., via a low data rate Internet connection, while other participants may be provided with aversion of the presentation that utilizes a high speed broadband Internet connection that in near real time supports two way network communication with such participants.
[0013] In one embodiment of the method and system of the present disclosure reports to contributors are automatically and/or periodically generated for distribution to the contributors of organizations or entities. Such reports may be of a financial nature and may be confidential to the contributor. Accordingly, a contributor may be utilizing the presently disclosed method and system for receiving such confidential information from a plurality of different or independent organizations or entities, such confidential information is disclosed selectively as specified by the contributor. Thus, the contributor may request all information relating to philanthropic contributions managed or accessed via the presently disclosed system and method (herein also identified as a “philanthropic management system”) be provided to him/herself, all information relating to a first collection of one or more philanthropic organizations or entities be provided to one or more specified individuals, and not providing any information related to the contributor's dealings with another second collection of one or more philanthropic organizations or entities. Moreover, the contributor's philanthropic related information across a plurality of charitable organizations or entities may be combined into a unified report for the contributor.
[0014] Additionally, a contributor may provide contribution rules or constraints to an embodiment of the present method so that changes in contribution amounts to various organizations or entities can be automatically implemented dependent upon, e.g., one or more of: (i) a total amount (or projected amount to be) in a trust fund, (ii) an amount of profit (or projected amount to be) made by such a trust, (iii) a yearly income received by a particular business, philanthropic organization or entity, or a particular individual, (iv) an age of a particular individual, (v) total maximum amount to be allocated for contributions, (vi) a priority or ranking of types of assets from which contributions are to be made. Thus, a contributor may specify rules such as the following rules:
(a) If charitable organization A's total net assets is greater than $1,000,000 then retain 5% of the contributor's annual contribution to A;
Else if the charitable organization A's total annual income for each of two consecutive years is less than $500,000, then add an additional 5% to the contributor's annual payment from retained amounts, and cease all payments if in the third year organization A's total annual income is less than $500,000.
(b) If a charitable organization B increases the number of orphans being housed increases 5% in any one year, then increase the contribution to B by 3%. (c) Cease (decrease or suspend) or commence (increase or re-commence) contributions to charitable organization C when a predetermined condition occurs, e.g., a particular individual reaches a certain age, contributor's total asset base falls below (rises above) a predetermined amount, the annual income of a particular person falls below (rises above) an inflation adjusted amount, the collective instructions from a predetermined group of individuals or entities, etc.
[0019] Accordingly, in one embodiment, the presently disclosed philanthropic management system may not only monitor a contributor's charitable or philanthropic giving, but also assist in the actual allocation of contributions according to, potentially complex, rules or instructions provided by the contributor. Additionally/alternatively, it is within the scope of the present disclosure that contributors may have access to financial tools for modeling their contributions into the future according to such rules, wherein, e.g., various scenarios may be generated by the philanthropic management system disclosed herein. In particular, such scenarios may be substantially more complex than merely assuming certain annual return rates of various asset types. For example, such scenarios may take into account historical information about what is likely to be the result on a given one or more charities (or types thereof) of an economic downturn in, e.g., the global (or a national) economy. Thus, the contributor may enter rules that try to balance competing needs for the contributor's contributions, wherein a balance may depend on both the likely economic health of one or more charitable organizations as well as the contributor's assets. Moreover, statistical (Markov) simulations may be performed providing contributors with information about likely outcomes such as when a trust fund would be likely to be depleted, under what circumstance would contributions to health related charities exceed contributions to drug addiction prevention related charities assuming economic fluctuations in the future can be approximated by economic fluctuations in the past.
[0020] In one embodiment of the philanthropic management system of the present disclosure provides training and/or configuration assistance for non-profit clients (e.g., charitable organizations and entities) and their staff via network (Internet communications. In particular, such training or assistance may assist such staff in profiling various types of contributors according to various characteristics, e.g., a geographical area(s) contributors reside, or contributor charitable giving history, or demographic group(s) such as: age group(s), income level group(s), educational level group(s), organization affiliation(s). Such profiling can be used to identify additional prospective contributors to a charitable organization or entity.
[0021] In one embodiment of the philanthropic management system of the present disclosure charitable organizations or entities may also be profiled for assisting contributors in diversifying their contributions over a plurality of such organizations or entities. For example, a contributor (advisor thereto) that has accessed the presently disclosed philanthropic management system for investigating contributing to a particular charity or non-profit organization may be provided with access to one or more of the following:
(a) Access to the identification of other philanthropic organizations or entities that other contributors to the particular charity or non-profit also contribute; (b) Contribution diversification or allocation information aggregately collected from other contributors having similar contributor profiles and/or interests; (c) Ratings of the performance of philanthropic organizations or entities, wherein such ratings are provided by the contributors thereto; (d) Access to an “intelligent” search engine(s) allowing a contributor to search for prospective philanthropic organizations or entities that may be of interest to the contributor, wherein, e.g., the contributor need not necessarily enter explicitly for such a search the information used by the engine(s), and the results may include information describing why each resulting philanthropic organization or entity is presented to the contributor.
[0026] In one embodiment of the philanthropic management system of the present disclosure, downloadable, customizable marketing materials may be provided to non-profit entity clients. Such materials may cover various topics pertinent to charitable giving, tax planning and estate planning.
[0027] In one embodiment of the philanthropic management system of the present disclosure, this management system may be branded for private-label of various client philanthropic organizations or entities. Such branding may be integrated into each such client's corresponding website.
[0028] In one embodiment of the philanthropic management system of the present disclosure professional advisors for facilitating/enabling planned contributions may also be profiled for assisting contributors in providing contributions. For example, a contributor may access the presently disclosed philanthropic management system for investigating such advisor(s) may be provided with access to one or more of the following:
(a) Access to the identification of such advisors that other contributors have used; (b) Information on advisor preferences aggregately collected from other contributors having similar contributor profiles and/or interests; (c) Ratings of the performance of such advisors, wherein such ratings are provide contributors that used such advisors; and (d) Access to an “intelligent” search engine(s) allowing a contributor to search for prospective advisors that may be of interest to the contributor, wherein, e.g., the contributor need not necessarily enter explicitly for such a search the information used by the engine(s), and the results may include information describing why each resulting advisor identified is presented to the contributor.
[0033] In one embodiment of the philanthropic management system of the present disclosure, an on-line, interactive, estate planning interactive guide (also referred to as an “estate planning agent”) which contributors can utilize to assist in (preparing for) drafting estate planning documents. This web based interactive planning guide can take contributors (or other users) step by step through an estate planning process, wherein a result therefrom may be: (i) initial drafts of certain documents and/or the information necessary for having such final documents drafted by a professional such as an estate planner or attorney. Such documents may include wills, revocable living trusts, bypass trusts, testamentary charitable remainder trusts, and children's trusts, etc. Note that the philanthropic management system may be used for securely submitting such initial document preparation information to one or more advisors, e.g., for allowing the contributor to obtain an initial consultation with the advisors, and for obtaining fee estimates. Such submissions may be conveyed electronically via the Internet.
[0034] In one embodiment of the philanthropic management system of the present disclosure a preferred collection of attorneys and/or other professionals may be accessed by the management system for selecting prospective professionals to be identified to a contributor. The selected prospective professionals may be selected according to their geographic proximity to the contributor (e.g., in a same city or metropolitan region as the contributor resides), fee structure for preparing estate planning and charitable contribution documents, special expertise of the professional, etc.
[0035] In one embodiment of the philanthropic management system of the present disclosure “belief” based in that the beliefs of the contributors and advisors are taken into account in identifying, selecting and determining how best to assist contributors in estate planning and charitable giving. In particular, for a client philanthropic organization utilizing a belief based philanthropic management system, such a management system may be characterized by:
(a) Determining, storing and providing documents and other information to contributors for the client philanthropic organization, wherein the documents and other information are at least consistent with (and preferably bolsters) the client philanthropic organization's beliefs and/or values relating to situations, circumstances and/or events that occur beyond the lifetime of the contributor (in particular, as such information relates to philanthropic giving). The stored documents and other information is accessible for transmittal to contributors on a communications network (e.g., the Internet); (b) Providing interactive network (Internet) communications between the client philanthropic organization or entity and one or more contributors for determining a financial or economic impact on each such contributor, wherein a quantitative financial or economic projection is provided to the contributor prior to the contributor consenting to a particular contribution, the projection showing a net negative financial or economic impact to the contributor and optionally his/her successors, and wherein the projection is based on financial or economic data; (c) Selecting and/or providing to the contributors contacts for professionals and/or other individuals with expertise relating to, e.g., scheduled or planned contributions via estate planning and legal issues related thereto, wherein such selected individuals have beliefs and/or values about situations, circumstances and/or events that occur beyond the lifetime of such individuals that are at least consistent with (and preferably bolsters) the client philanthropic organization's beliefs and/or values relating to situations, circumstances and/or events that occur beyond the lifetimes of individuals identified with the philanthropic entity and beyond the lifetimes of the professionals; (d) Filtering or deselecting professional contacts of individuals or entities having beliefs about situations, circumstances and/or events that occur beyond the lifetime of such individuals or entities that are at least inconsistent with the philanthropic organization's beliefs and/or values relating to situations, circumstances and/or events as described in (a) immediately above; and (e) Restricting, filtering and/or precluding the providing of documents, information, and contacts for individuals that expressly state or otherwise have advocated acts that are inconsistent with the philanthropic organization's beliefs and/or values relating to situations, circumstances and/or events that occur beyond the lifetimes of individuals identified with and attesting to beliefs and/or values of the philanthropic entity.
[0041] Such belief based features of the philanthropic management system are believed to be of particular interest to philanthropic organizations or entities, contributors, and advisors since it is believed that charitable giving is more belief driven than other financial exchanges.
[0042] In one embodiment of the philanthropic management system of the present disclosure, a preferred collection of attorneys and/or other professionals may be accessed by the management system for selecting prospective professionals to be identified to a contributor. The collection attorneys and/or other professionals may be selected for a particular client based on the values and beliefs of the contributor.
[0043] In one embodiment of the philanthropic management system of the present disclosure, legal services to clients' contributors may be provided with reduced legal rates. Such legal services are at no cost to the client.
[0044] In one embodiment of the philanthropic management system of the present disclosure, both the client philanthropic organizations and their contributors register with the management system for providing authenticated secure Internet communications.
[0045] In one embodiment of the philanthropic management system of the present disclosure, a turn-key charitable gift annuity system (including implementation and maintenance) is provided at no cost or reduced cost to a client philanthropic organization. For example, an operator of the philanthropic management system may receive compensation from the funding received from contributors to the client philanthropic organization, wherein such contributors utilized the management system. Alternatively/additionally, compensation to the operator of the philanthropic management system may receive a percentage of the annual income stream received from contributors to the client philanthropic organization, wherein such contributors utilized the management system.
[0046] The presently disclosed philanthropic management system is particularly beneficial for philanthropic entities or organizations that cannot afford the overhead of hiring one or more marketing and/or contributor care professionals. Since the management system disclosed herein provides common or similar services and materials to a potentially large number of philanthropic entities or organizations, much of the services and materials provided to clients can be based on generic services and materials that can be transformed into services and materials uniquely identified with each individual client. Such transformations are an important aspect of the functionality of the present management system.
[0047] Additionally, the presently disclosed philanthropic management system is particularly beneficial to philanthropic entities or organizations that have a very large number of contributors (e.g., 500,000) since it is financially infeasible for such an entity or organization to effectively communicate with such a large number of contributors for soliciting contributions of a potentially complex nature such as planned giving via, e.g., estate planning. Accordingly, since the transforming of generic marketing materials related to planned giving and reasons therefor can be spread over a plurality of philanthropic entities or organizations, the present management system is particularly cost effective for philanthropic entities or organizations with large numbers of contributors, particularly since charges for use of present management system to a philanthropic entity or organization may be substantially (or entirely) independent of the number contributors to the entity or organization.
[0048] Any combination of the above-identified aspects of the philanthropic management system identified above can be provided in an embodiment of such a system. Other features and benefits of the present disclosure are described in the accompanying figures together with the description hereinbelow. In particular, various features and/or embodiments of the philanthropic management system are set forth in the attached figures and in the description hereinbelow as described in the claims hereinbelow. Accordingly, it should be understood that this Summary does not contain all of the aspects and embodiments of the novelty disclosed herein. Thus, this Summary is not meant to be limiting or restrictive in any manner. Further, the invention(s) as disclosed herein is/are to be understood by those of ordinary skill in the art to encompass obvious improvements and modifications thereto.
BRIEF DESCRIPTION OF THE DRAWINGS
[0049] The Figures described below are a small portion of the website for an embodiment of the philanthropic management system of the present disclosure. Note that PCX in the figures is the name of philanthropic management system disclosed in the figures.
[0050] FIGS. A- 1 through A- 2 show a home page for an embodiment of the philanthropic management system of the present disclosure which gives an overview of the turn-key internet based planned giving system offered.
[0051] FIGS. B- 1 and B- 2 are a brief overview of for an embodiment of the philanthropic management system of the present disclosure introducing the services offered to clients.
[0052] FIG. C- 1 is a page from a client's website introducing the concept of Stewardship and Estate Planning to the contributors of a client philanthropic organization for an embodiment of the philanthropic management system of the present disclosure, wherein such introduction is consistent with the beliefs and/or values of the client, and is used to educate contributors regarding such beliefs as they relate to contributing to the client philanthropic organization.
[0053] FIGS. D- 1 through D- 2 are pages from a client philanthropic organization's website giving an overview of Stewardship in Estate Planning concepts to educate contributors of the client, wherein such overview is consistent with the beliefs and/or values of the client, and is used to educate contributors regarding such beliefs as they relate to contributing to the client philanthropic organization.
[0054] FIGS. E- 1 through E- 2 are pages from a client philanthropic organization's website containing testimonials from end users of the services provided by the philanthropic management system.
[0055] FIGS. F- 1 through F- 2 are pages from a client's website detailing the concept of Stewardship, wherein such overview is consistent with the beliefs and/or values of the client, and is used to educate contributors regarding such beliefs as they relate to contributing to the client philanthropic organization.
[0056] FIGS. G- 1 through G- 6 are pages from a client's website setting forth case studies of several different contributors' situations and life issues and how proper estate planning solved potential estate problems.
[0057] FIGS. H- 1 through H- 7 are pages from a client's website setting forth an “estate planning primer” which explains the basic tools of estate planning and how they are used.
[0058] FIG. I- 1 is a page from a client's website explaining how a contributor can get started in his or her estate planning process.
[0059] FIGS. J- 1 through J- 2 are pages from a website for the philanthropic management system describing some of the marketing material available to clients.
[0060] FIGS. K- 1 through K- 2 illustrate a flow diagram for an estate planning organizer according to an exemplary embodiment.
[0061] FIGS. L- 1 through L- 10 illustrate pages from a website for an estate planning organizer according to an exemplary embodiment.
DETAILED DESCRIPTION OF THE INVENTION
[0062] The definitions to the terms below are provided for convenience in understanding and do not serve to limit the scope or the general usage of these terms. In general, the terms below are also referenced in various portions of this document, of which those portions of this document may expand upon the definitions to the terms as given below.
[0063] “Clients” referred to in this application are philanthropic organizations or entities (e.g., charities or non-profit organizations) seeking to raise funds from among its contributors current donors and prospective new donors).
[0064] “Contributors” referred to in the present disclosure are individuals who have made or will make charitable contributions to a philanthropic organization or entity of their choice.
[0065] “Webinar” referred to in the present disclosure is a seminar conducted via a website for the philanthropic management system, which includes interactive features as well as pre-recorded material.
[0066] The phrases “at least one,” “one or more,” and “and/or” refer to open-ended expressions that are both conjunctive and disjunctive in operation. For example, each of the expressions “at least one of A, B and C,” “at least one of A, B, or C,” “one or more of A, B, and C,” “one or more of A, B, or C” and “A, B, and/or C” means A alone, B alone, C alone, A and B together, A and C together, B and C together, or A, B and C together.
[0067] The term “a” or “an” entity refers to one or more of that entity. As such, the terms “a” (or “an”), “one or more” and “at least one” can be used interchangeably herein. It is also to be noted that the terms “comprising,” “including,” and “having” can be used interchangeably.
[0068] The term “automatic” and variations thereof refers to any process or operation done without material human input when the process or operation is performed. However, a process or operation can be automatic, even though performance of the process or operation uses material or immaterial human input, if the input is received before performance of the process or operation. Human input is deemed to be material if such input influences how the process or operation will be performed. Human input that consents to the performance of the process or operation is not deemed to be “material.”
[0069] The term “computer-readable medium” refers to any tangible storage and/or transmission medium that participate in providing instructions to a processor for execution. Such a medium may take many forms, including but not limited to, non-volatile media, volatile media, and transmission media. Non-volatile media includes, for example, NVRAM, or magnetic or optical disks. Volatile media includes dynamic memory, such as main memory. Common forms of computer-readable media include, for example, a floppy disk, a flexible disk, hard disk, magnetic tape, or any other magnetic medium, magneto-optical medium, a CD-ROM, any other optical medium, punch cards, paper tape, any other physical medium with patterns of holes, a RAM, a PROM, an EPROM, a FLASH-EPROM, a solid state medium like a memory card, any other memory chip or cartridge, a carrier wave as described hereinafter, or any other medium from which a computer can read. A digital tile attachment to e-mail or other self-contained information archive or set of archives is considered a distribution medium equivalent to a tangible storage medium. When the computer-readable media is configured as a database, it is to be understood that the database may be any type of database, such as relational, hierarchical, object-oriented, and/or the like. Accordingly, the disclosure is considered to include a tangible storage medium or distribution medium and prior art-recognized equivalents and successor media, in which the software implementations of the present disclosure are stored.
[0070] The term “module,” refers to any known or later developed hardware, software, firmware, artificial intelligence, fuzzy logic, or combination of hardware and software that is capable of performing the functionality associated with that element.
[0071] The terms “determine,” “calculate,” and “compute,” and variations thereof are used interchangeably and include any type of methodology, process, mathematical operation or technique.
[0072] It shall be understood that the term “means” shall be given its broadest possible interpretation in accordance with 35 U.S.C., Section 112(f). Accordingly, a claim incorporating the term “means” shall cover all structures, materials, or acts set forth herein, and all of the equivalents thereof. Further, the structures, materials or acts and the equivalents thereof shall include all those described in the summary of the invention, brief description of the drawings, detailed description, abstract, and claims themselves.
[0073] Embodiments herein presented are not exhaustive, and further embodiments may be now known or later derived by one skilled in the art.
[0074] Functional units described in this specification and figures may be labeled as modules or outputs in order to more particularly emphasize their structural features. A module and/or output may be implemented as hardware, e.g., comprising circuits, gate arrays, off-the-shelf semiconductors such as logic chips, transistors, or other discrete components. They may be fabricated with Very-large-scale integration (VLSI) techniques. A module and/or output may also be implemented in programmable hardware such as field programmable gate arrays, programmable array logic, programmable logic devices or the like. Modules may also be implemented in software for execution by various types of processors. In addition, the modules may be implemented as a combination of hardware and software in one embodiment.
[0075] An identified module of programmable or executable code may, for instance, include one or more physical or logical blocks of computer instructions that may, for instance, be organized as an object, procedure, or function. Components of a module need not necessarily be physically located together but may include disparate instructions stored in different locations which, when joined logically together, include the module and achieve the stated function for the module. The different locations may be performed on a network, device, server, and combinations of one or more of the same. A module and/or a program of executable code may be a single instruction, or many instructions, and may even be distributed over several different code segments, among different programs, and across several memory devices. Similarly, data or input for the execution of such modules may be identified and illustrated herein as being an encoding of the modules, or being within modules, and may be embodied in any suitable form and organized within any suitable type of data structure.
[0076] In one embodiment, the system, components and/or modules discussed herein may include one or more of the following: a server or other computing system including a processor for processing digital data, memory coupled to the processor for storing digital data, an input digitizer coupled to the processor for inputting digital data, an application program stored in one or more machine data memories and accessible by the processor for directing processing of digital data by the processor, a display device coupled to the processor and memory for displaying information derived from digital data processed by the processor, and a plurality of databases or data management systems.
[0077] In one embodiment, functional block components, screen shots, user interaction descriptions, optional selections, various processing steps, and the like are implemented with the system. It should be appreciated that such descriptions may be realized by any number of hardware and/or software components configured to perform the functions described. Accordingly, to implement such descriptions, various integrated circuit components, e.g., memory elements, processing elements, logic elements, look-up tables, input-output devices, displays and the like may be used, which may carry out a variety of functions under the control of one or more microprocessors or other control devices.
[0078] In one embodiment, software elements may be implemented with any programming, scripting language, and/or software development environment, e.g., Fortran, C, C++, C#, COBOL, Apache Tomcat, Spring Roo, Web Logic, Web Sphere, assembler, PERL, Visual Basic, SQL, SQL Stored Procedures, AJAX, extensible markup language (XML), Flex, Flash, Java, .Net and the like. Moreover, the various functionality in the embodiments may be implemented with any combination of data structures, objects, processes, routines or other programming elements.
[0079] In one embodiment, any number of conventional techniques for data transmission, signaling, data processing, network control, and the like as one skilled in the art will understand may be used. Further, detection or prevention of security issues using various techniques known in the art, e.g., encryption, may also be used in embodiments of the invention. Additionally, many of the functional units and/or modules, e.g., shown in the figures, may be described as being “in communication” with other functional units and/or modules. Being “in communication” refers to any manner and/or way in which functional units and/or modules, such as, but not limited to, input/output devices, computers, laptop computers, PDAs, mobile devices, smart phones, modules, and other types of hardware and/or software may be in communication with each other. Some non-limiting examples include communicating, sending and/or receiving data via a network, a wireless network, software, instructions, circuitry, phone lines, Internet lines, fiber optic lines, satellite signals, electric signals, electrical and magnetic fields and/or pulses, and/or the like and combinations of the same.
[0080] By way of example, communication among the users, subscribers and/or server in accordance with embodiments of the invention may be accomplished through any suitable communication channels, such as, for example, a telephone network, an extranet, an intranet, the Internet, cloud based communication, point of interaction devices (point of sale device, personal digital assistant, cellular phone, kiosk, and the like), online communications, off-line communications, wireless communications, RF communications, cellular communications, Wi-Fi communications, transponder communications, local area network (LAN) communications, wide area network (WAN) communications, networked or linked devices and/or the like. Moreover, although embodiments of the invention may be implemented with TCP/IP communications protocols, other techniques of communication may also be implemented using IEEE protocols, IPX, Appletalk, IP-6, NetBIOS, OSI or any number of existing or future protocols. Specific information related to the protocols, standards, and application software utilized in connection with the Internet is generally known to those skilled in the art and, as such, need not be detailed herein.
[0081] In embodiments of the invention, the system provides and/or receives a communication or notification via the communication system to or from an end user. The communication is typically sent over a network, e.g., a communication network. The network may utilize one or more of a plurality of wireless communication standards, protocols or wireless interfaces (including LTE, CDMA, WCDMA, TDMA, UMTS, GSM, GPRS, OFDMA, WiMAX, FLO TV, Mobile DTV, WLAN, and Bluetooth technologies), and may be provided across multiple wireless network service providers. The system may be used with any mobile communication device service e.g., texting, voice calls, games, videos, Internet access, online books, etc.), SMS, MMS, email, mobile, land phone, tablet, smartphone, television, vibrotactile glove, voice carry over, video phone, pager, relay service, teletypewriter, and/or GPS and combinations of the same.
[0082] Embodiment includes a web based system to educate, motivate and empower individual contributors to make charitable gifts to philanthropic organizations or entities having similar beliefs and/or values as described in the Summary section hereinabove.
[0083] In one embodiment of philanthropic management system, all information, presentations and advisor contacts are based on Judeo-Christian beliefs and/or values as related to situations, circumstances and/or events that occur beyond the lifetimes of individuals identified with the philanthropic entity. However, other beliefs and/or values are also within the scope of the present disclosure. For example, an embodiment of the philanthropic management system may also assist philanthropic organizations or entities in obtaining contributions, wherein such an organization or entity may be directed to environmental issues, and accordingly hold and espouse beliefs and/or values as related to situations, circumstances and/or events that relate, e.g., to reducing the effects of man made climate changes occurring both now and beyond the lifetimes of individuals identified with the philanthropic entity, and/or saving endangered species.
[0084] In one embodiment, the philanthropic management system has various Internet interfaces. A first such interface is for accessing a primary website that is accessible by the general population of Internet users, but is primarily intended for the clients of the management system, wherein clients (e.g., philanthropic entities or organizations) can access materials for marketing giving plans to contributors.
[0085] For each client philanthropic entity subscribing to the services offered by the philanthropic management system, an additional interface is available for the contributors to the philanthropic entity. Each such additional interface is tailored to identify the client, the client's unique logo, etc.
[0086] When a contributor and/or client subscribes to (or registers for) the services of the philanthropic management system, such subscribers have access to study courses, online seminars, up to date web based information, marketing materials, legal professionals and more.
[0087] Once a client subscribes to the services of the philanthropic management system, the website therefor can be tailored to that client, using their logos and slogans, and generally looking like a part of the client's website. The tailor made website is then linked into the client's website for seamless navigation by the client's contributors.
[0088] When a client's contributors are navigating the client's website, they can link to an embodiment of the philanthropic management system, including an Estate Plan Organizer, which they can fill out in private, send securely to philanthropic management system, who can then contact them with options for a successful estate plan. Other links from the client website may include an overview of estate planning issues, a client perspective of stewardship, gift opportunities, case studies, and general statistics and ideas from other “real life” contributors. Contributors are also given the opportunity to seek the assistance of an attorney from a preferred network of attorneys (at a reduced fee). This network of attorneys may utilize the services of a third party company. This network of attorneys providing local legal advice to contributors is an important aspect that heretofore prevented or inhibited clients from getting their contributors from the stage of intending to make a client contribution to fully executing a charitable gift plan.
[0089] FIGS. K- 1 through K- 2 illustrate a flow diagram for an estate planning organizer according to an exemplary embodiment.
[0090] In an embodiment, the estate plan organizer is put together and organized in accordance with the teachings of the Bible. Organized through a study of the Bible with an understanding of the responsibility of stewardship and put together to comport with the rules of modern estate planning, the estate plan organizer offers a novel and beneficial method and system for anticipating and planning the disposal of an estate for a Christian.
[0091] In one aspect, the estate plan organizer reminds users that God is the owner of all of our resources, that we are merely stewards. Consequently, the largest stewardship decision we will ever make will be through an estate plan. As such, in estate planning in accordance to the Bible, we are merely arranging to transfer stewardship responsibly, hopefully in a way that would please the One who is created and owns all things. He said in Psalm 50: 10-12,
for every animal of the forest is mine, and the cattle on a Thousand Hills. I know every bird in the mountains, and in the creatures of the field are mine. If I were hungry I would not tell you, for the world is mine, and all that is in it.
[0093] According to an embodiment, the estate plan organizer comports to two overriding Biblical principles that are relayed in the estate plan organizer to guide people to wisely steward their estates. The first is dependency. As stated in 2 Timothy 5:8, we are “worse than an infidel if we fail to take care of those in the household of faith.” Thus, the first priority in transferring ownership is to take care of all dependents. The second overriding consideration is love, as Christians are called to love our neighbor as ourselves and be generous with what God has entrusted to us. As Jesus stated in Matthew 25:34-40,
Then the king will say to those on his right, ‘Come you who are blessed by my Father. Inherit the kingdom prepared for you from the foundation of the world. For I was hungry and you gave me food, I was thirsty and you gave me drink, a stranger and you welcomed me, naked and you clothed me, ill and you cared for me, in prison and you visited me’. Then the righteous will answer him and say ‘Lord, when did we see you hungry and feed you, or thirsty and give you drink? When did we see you a stranger and welcome you, or naked and clothe you? When did we see you ill or in prison, and visit you?’ And the king will say to them in reply ‘Amen, I say to you, whatever you did for one of these least brothers of mine, you did for me.’
The estate plan organizer utilizes at least these two principles, dependency and love, to guide people in making these important estate distribution decisions.
[0095] The estate planning organizer begins with notifying the user of the stewardship decision making in step 102 . This may serve as a remainder to users that God owns all resources and that these stewardship decisions are not ownership decisions as explained above in accordance with the Bible. Further, the users are reminded of the dependency and love criteria as explained above.
[0096] The estate planning organizer asks user for general children and charity information in step 104 . Here, the estate planning organizer may ask information about the user's children (e.g., ages, personal situation such as marital status, etc.). Here, the estate planning organizer also reminds the user that his first responsibility is to care for dependents and particularly for a permanent dependency such as evidenced with a special needs child.
[0097] To take users through this journey of stewarding their estates, early in the estate planning organizer right after asking about the user's children, the user is strategically asked about charities that the user supports. Here, the estate planning organizer also reminds the user that the charities that he supports and loves have also become dependent upon support and are worthy beneficiaries through the user's estate. By coupling the two: children and charities, the probability that the user will realize that it makes sense to designate a gift to charity through his estate is greatly increased.
[0098] The estate planning organizer receives user information regarding the estate in step 106 . This may include various questions regarding the estate to determine the estate value and composition.
[0099] The estate planning organizer receives user information regarding the dependency. This may include all types of dependents including older dependents (e.g., parents, siblings) and children.
[0100] For older dependents 110 , if the user will need to prepare for older dependents, the estate planning organizer may recommend a charitable remainder trust for these dependents to provide income for life at a desired level (e.g., with an inflation hedge) 112 .
[0101] For children 114 , if the user has children, the estate planning organizer may consider if the child is a minor 116 or has special needs 120 . If the child is a minor 116 , the estate planning organizer may recommend a children's trust to hold assets for the child until the child reaches a desired age (e.g., an age of financial maturity) and then distribute assets to beneficiaries or charities. If the child has special needs (e.g., have serious health issues that likely require long term assistance), the estate planning organizer may recommend a special needs trust for the child. Further, the special needs trust may be arranged to have all assets allocated to it is the need is great or uncertain enough. As such, the estate planning organizer may recommend to exclude any charitable distribution from plan and recommend distribution of reserving assets for special need.
[0102] It is noted that a user may have multiple dependents or no dependents based on the situation of each user.
[0103] Once the user has planned for his dependents and decides to give through their estate, the estate planning organizer can help the user to decide how much to give to charity. The estate planning organizer mentions a tithe (10%) just because this is a very familiar Biblical concept. The estate planning organizer may also steer the user towards the concept of another child called “charity” again reminding them that the charities that they have loved and supported have become somewhat dependent. Here, a family with three children would carve the estate into four equal parts, giving each of the children 25% of the estate, and dividing the remaining 25% among the ministries they want to benefit.
[0104] Also, higher net worth individuals may typically conclude that leaving too much to their children can be harmful rather than helpful, preventing them from developing good work habits and a reliance on God rather than material possessions. Upon reflection of Genesis 3:19, “by the sweat of your brow you shall eat bread,” these individuals will often decide to cap the children's inheritance and leave the balance to the charitable organizations that they care about.
[0105] The estate planning organizer receives user information regarding intended distribution of estate to charity in step 124 . Here, the user may decide to give a percentage to charity (e.g., similar to a tithe amount of 10%) 124 A, treating charity as a child 124 B, passing the remainder to charity 124 C or no distribution to charity (e.g., all assets are distributed to children and/or family) 124 D.
[0106] The estate planning organizer determines the distribution of the estate based on the received user information in step 126 . In an embodiment, the estate planning organizer may determine or aid the user in determining the amount to be distributed to each of the dependents or charities. For example, the estate planning organizer may first determine the amount to be distributed to charity (e.g., based on the user information from step 124 ) and any amounts to be distributed to other family members or heirs that are not children or dependents (e.g., based on other user information). These amounts can be adjusted from the total estate value. Next, the estate planning organizer may determine the amount that will be distributed to the dependents (e.g., based on the types of dependents and the trust recommended in steps 108 through 122 ) from the adjusted estate value. In one aspect, each child (and charity child) may receive an equal amount. The amount for each child may be further adjusted by an amount representing an approximated annual income from a trust (e.g., 10%).
[0107] The estate planning organizer informs and adjusts the inheritance based on the user information in step 128 . Here, the user may be reminded that most inheritances are squandered within 18 months. As the inheritance for each child is calculated, the user may be informed and asked if the child is able to handle such an inheritance responsibility. In an embodiment, if the user decides that a child cannot handle such an inheritance responsibility, the estate planning organizer may recommend that the inheritance be in a form of an income stream (e.g., from a charitable remainder trust). Other children that can handle such inheritance responsibility may be allowed to received their inheritance immediately, in another embodiment, the estate planning organizer may ask the user to reevaluate a child's situation in step 108 . For example, the user may be asked to reevaluate a child as one with a special need to guarantee an income stream for life.
[0108] The estate planning organizer may also determine that the amount for each child may be too high such that it may be a disincentive to the development of good work habits and reliance on God. For example, if the amount exceeded some adjusted percentage (e.g., adjusted to inflation) of the user's own standard of living at the time when the user was a child, this may be determined to be too high for the user's children. In other embodiments, other standards (e.g., standard of living for children in the area in general, fixed amounts, etc.) may be used as the criteria for this determination.
[0109] The estate planning organizer confirms and calculates distribution to the intended charities in step 130 .
[0110] Once it has been determined how much to leave to charity, the estate is careful to lead the user through decisions on how best to distribute wealth to the charities. Good stewardship involves not only deciding to whom to transfer management, but also how best to transfer management. As discussed above, for distributions to children, the estate planning organizer helps the user examine whether the children are ready to receive a significant inheritance and to steward the wealth wisely. If not, a trust is recommended to protect against this and sometimes a charitable trust is recommended for this purpose. For distribution to charities, sometimes a bequest can be distributed all at once, but in some instances the size of the bequest may be very large compared to the charity's operating budget, making it wise to have the distribution take place in smaller increments over a series of years. In other instances, particularly where there is permanence to the need of the charitable organization, such as caring for the poor, and educating, the best solution may be to make these contributions in the form of an endowment to provide ongoing support. Genesis 41 provides a Biblical illustration of the wisdom of this approach. Here God used Joseph to cause the king of Egypt to order an unprecedented storage of grain against the coming seven years of famine. Through that endowment the people were kept from starvation. The estate planning organizer presents solutions for all of these types of distributions.
[0111] The estate planning organizer may ask the user for the list of charitable beneficiaries from the estate. Typically, this may be the same list or a subset of the list that was detailed in step 104 (charities presently supporting). The user may then be asked for the percentage of the total charitable distribution that will be allocated to each charity. For each charitable beneficiary, calculate the amount that they would receive if the estate were settled today, and then go through the following determination:
[0112] 1. Ask if the charity might be better served by ongoing contributions rather than a one-time distribution 132 . This is often viewed as the case when the need that the charity is filling has permanence, such as providing for the poor. If yes, the estate planning organizer may recommend that this portion of the charitable gift be directed to a foundation 136 to provide ongoing support to the name charity through an endowment 136 .
[0113] 2. Ask if the size of the bequests that the charity will receive is very large in relationship with their annual budget 134 . If so, the estate planning organizer may recommend that this portion of their charitable distribution be directed through a foundation 136 , that would in turn distribute the funds to the desired the charity over a period of years. The estate planning organizer may further determine the period of years that makes the amount reasonable in relationship to the charity's budget.
[0114] 3. If the answer is no to both questions above, the estate planning organizer may determine that a foundation is not needed for the charity's, distribution, and the charity can be named within the estate documents to receive the distribution immediately upon settlement of the estate.
[0115] The estate planning organizer informs the user on estate instruments and costs in step 138 . The estate planning organizer may explain the utilization/benefit of wills and revocable living trusts for estate documents, and advise on probate costs in their state. The estate planning organizer may also ask for the user's preference between utilizing wills or a revocable living trust and obtain selections for personal representatives, trustees, power of attorneys.
[0116] The estate planning organizer informs the user on suitable professionals in step 140 . The information above are summarized and organized for an attorney. The estate planning organizer may further specify the drafting price from one of the network attorneys, and facilitate the user's engagement with the network attorney if this option is selected.
[0117] FIGS. L- 1 through L- 10 illustrate pages from a website for an estate planning organizer according to an exemplary embodiment.
[0118] In an embodiment, the estate planning organizer may be further incorporated into the client's website (e.g., for the various organizations). In an aspect, the client's website may include unique page copy for each client and to fit into the body of the client's website page with content from the philanthropic management system. For example, the administrate of each client's website may create the embedded the unique pages from the philanthropic management system to the client's website using the Microsoft iframe tags. Installing to a client's website on a remote server may be similar to videos embedded to websites on remote servers (e.g., by YouTube or Vimeo).
[0119] In an embodiment, when prospective donors (users) register for their personal account, they are taken through a unique estate planning process, from a Biblical perspective. The experience is enhanced through graphics showing customized estate plans, including flow charts depicting amounts to children and charities, and also with invitations for personalized assistance whenever needed.
[0120] In an embodiment, client (e.g., administer of the client's website) accessing the philanthropic management system may be provided with an administive panel. Through this panel, the client can add/edit/delete page copy for all estate planning organizer pages including the addition of client/organization specific photos or images, donor stories and testimonials, and customization of the translation of Biblical references.
[0121] In an embodiment, when a user leaves an instance of the estate planning organizer (e.g., through a client's customized website) without finishing, the user may be automatically receive a series of motivational emails generated by the system to encourage the users to return and move forward in completing their documents. These emails may highlight the benefits to finish, ease of the process through the estate planning organizer, and eliminate barriers to finishing. The content of these emails will take into account the sections completed in the estate planning organizer, and in particular those sections skipped or portions left incomplete. The client, through the administive panel, may edit the content of all of these emails, and the rate or schedule at which they are sent. The client may also receive extensive website statistics to monitor estate planning organizer traffic, along with open rates on and return rates to monitor effectiveness of the motivational emails.
[0122] In further embodiment, additional features of the estate planning organizer may include:
[0123] Based on information input in the estate planning organizer regarding net worth, ages, type of assets, the estate planning organizer will be able to determine the individuals that are candidates for specific lifetime planned gifts, and generate emails promoting these concepts, with contact forms for additional information, consultations, and invitations to webinars to learn more.
[0124] Based on information input, the system may identify needs for other services (wealth management, business succession planning, life insurance) and connect individuals with advisors that share their faith for these services.
[0125] For individuals that start but do not finish the estate planning organizer, the system may identify those that are excellent estate gift candidates, such as couples without children, older single individuals that have never married, and individuals with larger estates that exhibit high charitable intent. The system will automatically alert client charity with name and address of these individuals along with a specific charitable estate planning message most likely to draw individuals into more personalized assistance.
[0126] The estate planning organizer may be set up to identify users that are influential at the ministry/client, and in positions to make direct referrals of other supporters of the ministry/client. For instance for a church client the system will identify individuals that teach Sunday school classes or Bible studies, and automatically send them information to utilize in their classes, helping them refer others to the estate planning organizer.
[0127] The foregoing discussion of the invention has been presented for purposes of illustration and description. Further, the description is not intended to limit the invention to the form disclosed herein. Consequently, variation and modification commiserate with the above teachings, within the skill and knowledge of the relevant art, are within the scope of the present invention. The embodiment described hereinabove is further intended to explain the best mode presently known of practicing the invention and to enable others skilled in the art to utilize the invention as such, or in other embodiments, and with the various modifications required by their particular application or uses of the invention.
[0128] Also, while the flowcharts have been discussed and illustrated in relation to a particular sequence of events, it should be appreciated that changes, additions, and omissions to this sequence can occur without materially affecting the operation of the disclosed embodiments, configuration, and aspects.
[0129] A number of variations and modifications of the disclosure can be used. It would be possible to provide for some features of the disclosure without providing others.
[0130] In yet another embodiment, the systems and methods of this disclosure can be implemented in conjunction with a special purpose computer, a programmed microprocessor or microcontroller and peripheral integrated circuit element(s), an ASIC or other integrated circuit, a digital signal processor, a hard-wired electronic or logic circuit such as a discrete element circuit, a programmable logic device or gate array such as PLD, PLA, FPGA, PAL, special purpose computer, any comparable means, or the like. In general, any device(s) or means capable of implementing the methodology illustrated herein can be used to implement the various aspects of this disclosure. Exemplary hardware that can be used for the disclosed embodiments, configurations and aspects includes computers, handheld devices, telephones (e.g., cellular, Internet enabled, digital, analog, hybrids, and others), and other hardware known in the art. Some of these devices include processors (e.g., a single or multiple microprocessors), memory, nonvolatile storage, input devices, and output devices. Furthermore, alternative software implementations including, but not limited to, distributed processing or component/object distributed processing, parallel processing, or virtual machine processing can also be constructed to implement the methods described herein.
[0131] In yet another embodiment, the disclosed methods may be readily implemented in conjunction with software using object or object-oriented software development environments that provide portable source code that can be used on a variety of computer or workstation platforms. Alternatively, the disclosed system may be implemented partially or fully in hardware using standard logic circuits or VLSI design. Whether software or hardware is used to implement the systems in accordance with this disclosure is dependent on the speed and/or efficiency requirements of the system, the particular function, and the particular software or hardware systems or microprocessor or microcomputer systems being utilized.
[0132] In yet another embodiment, the disclosed methods may be partially implemented in software that can be stored on a storage medium, executed on programmed general-purpose computer with the cooperation of a controller and memory, a special purpose computer, a microprocessor, or the like. In these instances, the systems and methods of this disclosure can be implemented as a program embedded on personal computer such as an applet, JAVA® or CGI script, as a resource residing on a server or computer workstation, as a routine embedded in a dedicated measurement system, system component, or the like. The system can also be implemented by physically incorporating the system and/or method into a software and/or hardware system.
[0133] Although the present disclosure describes components and functions implemented in the aspects, embodiments, and/or configurations with reference to particular standards and protocols, the aspects, embodiments, and/or configurations are not limited to such standards and protocols. Other similar standards and protocols not mentioned herein are in existence and are considered to be included in the present disclosure. Moreover, the standards and protocols mentioned herein and other similar standards and protocols not mentioned herein are periodically superseded by faster or more effective equivalents having essentially the same functions. Such replacement standards and protocols having the same functions are considered equivalents included in the present disclosure.
[0134] The present disclosure, in various aspects, embodiments, and/or configurations, includes components, methods, processes, systems and/or apparatus substantially as depicted and described herein, including various aspects, embodiments, configurations embodiments, subcombinations, and/or subsets thereof. Those of skill in the art will understand how to make and use the disclosed aspects, embodiments, and/or configurations after understanding the present disclosure. The present disclosure, in various aspects, embodiments, and/or configurations, includes providing devices and processes in the absence of items not depicted and/or described herein or in various aspects, embodiments, and/or configurations hereof, including in the absence of such items as may have been used in previous devices or processes, e.g., for improving performance, achieving ease and/or reducing cost of implementation.
[0135] As the foregoing discussion has been presented for purposes of illustration and description, the foregoing is not intended to limit the disclosure to the form or forms disclosed herein. In the foregoing description for example, various features of the disclosure are grouped together in one or more aspects, embodiments, and/or configurations for the purpose of streamlining the disclosure. The features of the aspects, embodiments, and/or configurations of the disclosure may be combined in alternate aspects, embodiments, and/or configurations other than those discussed above. This method of disclosure is not to be interpreted as reflecting an intention that the claims require more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive aspects lie in less than all features of a single foregoing disclosed aspect, embodiment, and/or configuration. Thus, the following claims are hereby incorporated into this description, with each claim standing on its own as a separate preferred embodiment of the disclosure.
[0136] Moreover, though the description has included a description of one or more aspects, embodiments, and/or configurations and certain variations and modifications, other variations, combinations, and modifications are within the scope of the disclosure, e.g., as may be within the skill and knowledge of those in the art, after understanding the present disclosure. It is intended to obtain rights which include alternative aspects, embodiments, and/or configurations to the extent permitted, including alternate, interchangeable and/or equivalent structures, functions, ranges or steps to those claimed, whether or not such alternate, interchangeable and/or equivalent structures, functions, ranges or steps are disclosed herein, and without intending to publicly dedicate any patentable subject matter. | A management system for managing, streamlining and automating the process of obtaining contributions for philanthropic entities (e.g., charities and other non-profit organizations), wherein user friendly Internet based processes are provided to (potential and actual) contributors that substantially eases the burden on such contributors in, e.g., contributing to such entities via planned giving or estate planning. For each of the philanthropic entities, the management system automates and facilitates the marketing and estate planning aspects for obtaining contributions in a manner that is consistent with the avowed beliefs and/or values of the entity, and that provides potential and actual contributors with contacts to professionals that also share the beliefs and/or values of the entity. | 6 |
REFERENCE TO RELATED APPLICATION AND PRIORITY CLAIM
This application expressly claims the benefit of earlier filing date and right of priority from the following patent application: U.S. Provisional Application Ser. No. 60/239,537 filed on Oct. 10, 2000 in the names of Charles A. Wilkins and James O. Stoneburner. The entirety of that earlier-filed, co-pending patent application is hereby expressly incorporated herein by reference.
FIELD OF THE INVENTION
This invention relates generally to treatment of septic tank effluent before it is discharged to a drain field, and more particularly it relates to systems and apparatus for straining the effluent.
BACKGROUND OF THE INVENTION
Certain wastes introduced into a septic tank tend to separate into distinct layers: a bottom sludge layer, a top scum layer, and a noticeably distinct intermediate liquid layer that is to a large extent free of scum and sludge. As waste accumulates, liquid is periodically pumped out of the tank as effluent that is discharged to a drain field. An electric-operated pump is typically used for pumping, and it is desirable to communicate the suction inlet of the pump to the intermediate layer because that layer is generally freer of solids and particulate matter than are the scum and sludge layers.
To avoid the entry of undesired particulate matter into the pump, a stationary screen may be used to screen the liquid before it enters the pump. The particle size that can be effectively strained is determined by the screen mesh. Generally speaking, the finer the mesh, the smaller the particle that can be screened; however, the finer the mesh, the greater the tendency for the screen to clog. Actual screen mesh size may be a compromise based on conflicting factors. Because a screen is typically disposed within a tank or within a vault that is disposed within a tank, it may be inconvenient to regularly clean. Because a homeowner may not maintain a septic tank at the intervals recommended by a manufacturer, a manufacturer may decide that the mesh of a strainer screen may be deliberately sized more coarsely to guard against clogging due to lack of homeowner maintenance. This means that larger particulate material may enter the pump, and while this may be undesirable as far as the pump is concerned, it may be deemed preferable to the risk of screen clogging.
Commonly assigned U.S. Pat. No. 6,231,764 of Charles A. Wilkins discloses a pump arrangement, including a self-cleaning rotary strainer that is effective in straining liquid that is pumped out of a septic tank as effluent to a drain field.
The exemplary pump arrangement disclosed in that patent comprises an electric-motor-operated effluent pump disposed generally upright, and coaxially within, an upright main tube that extends downward from a top wall of a septic tank to a location at or near a bottom wall of the tank. The tube passes through the top scum layer, through the intermediate liquid layer, and into the bottom sludge layer. Sensors, or switches, that sense the level of waste in the tank control operation of the pump. When the level rises beyond an upper limit, the pump operates to pump fluid out of the tank until the level drops to a lower limit at which the pump shuts off.
A strainer strains liquid entering the main upright tube from the intermediate layer, and includes a cylindrical filter screen disposed coaxial with the tube to constrain the effluent to flow radially through the filter screen and into the interior of the strainer. An electric pump unit is disposed coaxially within the tube and comprises an inlet port which is disposed downstream of the strainer along the direction of effluent flow through the system. The effluent provides some cooling of the motor as it flows along the motor exterior toward the inlet port where it enters the pump unit. An outlet pipe that is communicated to an outlet port at which pumped effluent exits the pump unit conveys pumped effluent out of the septic tank.
A nozzle is communicated to the pump unit outlet port and arranged to emit some of the pumped effluent toward the cylindrical filter screen opposite the effluent flow through the filter screen so as to cause the filter screen to be acted upon by both radial and circumferential flow components. A journal mounts one of the screen and the nozzle for rotation relative to the other such that effluent emitted from the nozzle is effective both to turn the screen and nozzle relative to each other and to dislodge debris from the filter screen.
In some embodiments, the nozzle is disposed within the interior of the strainer and arranged to emit effluent in a radially outward direction, and the flow of effluent through the filter screen is radially inward toward the interior of the strainer. In others, the nozzle is disposed in the exterior of the strainer and arranged to direct effluent radially inward toward the interior of the strainer, and the flow of effluent through the filter screen is radially outward toward the exterior of the strainer.
It is believed that the self-cleaning action enables the screen to have a finer mesh, yet avoid clogging, when the septic system is used in compliance with manufacturer recommendations. In a septic system where strainer clogging may be a limiting factor, the system disclosed in the Wilkins patent can offer the potential for extending the length of time between maintenance intervals.
SUMMARY OF THE INVENTION
The present invention relates to further improvements in self-cleaning septic tank strainers. Various embodiments of improvements are disclosed, and each possesses certain unique features within generic aspects of the present invention. The strainers use materials that are suited to provide long service life, but when needed, service may be conveniently accomplished. The inventive strainers are adapted for retrofitting existing septic systems, as well as for installation as original equipment in new septic systems.
Moreover, various embodiments make the inventive strainer suitable for use in various types of septic systems. Certain embodiments are suited for use with electric-motor-operated effluent pumps of the type described at length above with reference to the Wilkins patent. Certain embodiments are suited for use with other types of septic tank pumps that comprise electric-operated pumps housed within pump vaults that are disposed within septic tanks. Certain embodiments are intended for integrated assembly with a pump to form a pump/strainer unit that can be installed within a septic tank. Certain embodiments can provide for the strainer to be remotely located from the pump. Strainers that embody principles of the invention can be used in single and multiple septic tank systems.
A general aspect of the invention relates to a system for straining liquid pumped as effluent from a septic tank to a drain field. The apparatus comprises a strainer for straining liquid that is being pumped out of a septic tank by a pump before the liquid enters the pump. The strainer comprises a straining screen through which the pump draws the liquid. Solid material that is sucked against a face of the screen by pump suction is dislodged from the screen by returning some of the pumped effluent to a nozzle that is aimed toward the screen. The effluent emitted from the nozzle can act on a limited area of the screen while liquid is drawn through the remaining screen area. The screen and nozzle move relative to one another so that the area of the screen being acted on by the effluent from the nozzle is continually changing. This relative motion eventually enables the full extent of the screen to be cleaned, with the cleaning being repeated as long as the pump continues to operate.
The various embodiment of the invention provide for different types of relative motion and different screen and nozzle geometries. The nozzle may be stationary while the screen moves, or alternatively the screen may be stationary while the nozzle moves. The nozzle may execute either rotary motion or oscillatory motion. The screen may have a circular annular shape that extends 360° about an axis. The screen may be mounted on a wall in covering relation to a hole in the wall, and as such may be either flat or curved.
Because a septic tank that comprises a self-cleaning strainer embodying principles of the present invention allows the screen to have a finer mesh, yet avoid clogging, any particles that pass through the screen will have a smaller size. The pump is therefore not taxed by larger size particles, there is less likelihood that the nozzle or nozzles that clean the screen will clog. Because the inventive strainer prevents larger particles from being pumped out of the tank with the effluent, it may also be helpful in extending the useful life of a drain field.
The foregoing features, advantages, and benefits of the invention, along with additional ones, will be seen in the ensuing description and claims, which are accompanied by drawings. The drawings disclose a presently preferred embodiment of the invention according to the best mode contemplated at this time for carrying out the invention.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 shows an elevation view, partly broken away, of a first embodiment in accordance with principles of the present invention.
FIG. 2 shows an elevation view of a second embodiment.
FIG. 3 is a vertical cross section view in the direction of arrows 3 — 3 in FIG. 2 .
FIG. 4 is a view similar to FIG. 3, showing a modification.
FIG. 5 is a vertical cross section view through another embodiment.
FIG. 6 is a vertical cross section view through another embodiment similar to FIG. 5 .
FIG. 7 is a vertical cross section view through still another embodiment.
FIG. 8 is a vertical cross section view through still another embodiment similar to FIG. 7 .
FIG. 8A is a vertical elevation view, in cross section, through an exemplary septic tank containing a pump-strainer unit according to principles of the invention.
FIG. 9 is a vertical cross section view through still another embodiment.
FIG. 10 is a vertical cross section view through still another embodiment.
FIG. 11 is a vertical cross section view through still another embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a self-cleaning septic tank strainer 302 . The strainer may be associated with a pump in any of several different ways. One way is to dispose strainer 302 in underlying relation to the bottom horizontal wall 300 of a pump vault 292 so that both pump vault 292 and strainer form a unit that is supported within a septic tank 290 in any suitable manner. Preferably the unit is supported such that strainer 302 is disposed in the intermediate zone of the septic tank. Pump vault 292 contains a pump, shown schematically at 291 , that when running, is effective to draw liquid through strainer 302 .
Strainer 302 comprises a circular perforated screen 304 supported uprightly on the outer margin of an imperforate horizontal circular bottom wall 306 . The screen is retained in a circular shape by uprights, or posts, 308 . The upper ends of posts 308 join to an imperforate rim 310 that is stepped to provide an outwardly directed horizontal flange 312 that is supported on a circular ledge 314 forming the margin of a circular hole 316 in wall 300 . Flange 312 is captured on ledge 314 by an overlying wall 318 which has a flanged circular hole 320 at its center and is formed as part of bottom wall 300 as shown. When the pump is drawing liquid through the strainer, the liquid flows in the direction of the arrows 321 , passing through screen 304 and thence upward through hole 320 to the pump inlet. The pump pumps the liquid as effluent through a discharge pipe 323 ultimately leading to a drain field.
Adjacent hole 320 , a supply pipe 322 , that is teed into discharge pipe 323 through which the pump pumps effluent, extends through wall 318 to terminate in one or more nozzles 324 facing the interior side of the circular screen 304 . Supply pipe 322 conveys some of the pumped effluent to the nozzle(s). The nozzle(s) are arranged at a suitable angle not only to clean the screen but also to impart a horizontal force that is effective to rotate strainer 302 about a vertical centerline CL that is shared by the strainer, the screen, flange 312 , and hole 320 . In this way the screen rotates past the nozzle(s) where it will be continuously cleaned by the nozzle(s) to dislodge accumulated debris from the exterior side of the screen. Because a limited circumferential extent of the screen is being cleaned at any given time, liquid can be drawn through the remainder of the screen to be pumped as effluent. Joints of the upper and lower edges of the circular screen are tight to the bottom wall and the rim so that debris will not be sucked through the joints. Flange 312 has close running clearance to the crevice within which it is captured between walls 300 and 312 .
Alternatively, wall 300 can be a separate wall that is disposed against the bottom wall of a pump vault with hole 320 positioned in registration with a suction inlet of the pump extending through the vault bottom wall.
Another way to associate strainer 302 with a pump is like the way described in commonly assigned U.S. Pat. No. 6,231,764 where wall 300 is disposed within the interior of a cylindrical vault tube. Suitable modification is made to the strainer so that it will fit to the axial flow type pump shown in that patent.
FIGS. 2 and 3 illustrate a second embodiment of strainer 330 that comprises a circular imperforate cup 332 having an open upper rim 334 that is fit tight to wall 300 to prevent debris intrusion between them. The side wall of the cup comprises a circular hole 336 that is covered by a perforated screen 338 having a tight fit of the screen edge to the margin of the hole to prevent debris intrusion between them. Wall 300 forms the bottom of the pump vault 292 containing pump 291 that draws liquid through the screen to pump out the septic tank. A tap 340 at the pump outlet returns some of the pumped effluent through supply pipe 322 for cleaning the screen.
A rotary spray arm 342 is mounted within the interior of cup 332 , and contains one or more nozzles 344 aimed at the interior side of screen 338 . The liquid pressure delivered to spray arm 342 is effective to cause it to rotate about a horizontal axis that intersects the center of the screen as sprays are also being emitted from its nozzles. Because the nozzles spray only a limited area of the screen at any given instant of time to dislodge debris from the exterior of the screen, the remainder of the screen remains open so that the pump can draw liquid through it. It is believed beneficial to place a wall 346 over the screen in relatively close outwardly spaced relation to limit the influence of the nozzle spray on the unfiltered waste.
The second embodiment can be modified to an embodiment (not shown by a drawing) wherein such a rotary spray arm is mounted above the level of wall 300 to emit spray toward an existing screen in the side wall of a tube mounted within the vault within which the pump is disposed.
FIG. 4 shows an embodiment that has a strainer like the one of FIGS. 2 and 3. It differs in that it allows the pump to be remotely located with the suction inlet of the pump being coupled to the strainer interior by a suction tube 350 .
FIG. 5 shows another embodiment where a pump/strainer unit 500 is disposed within a vault 502 having a closed bottom wall 504 and a side wall 506 . Unit 500 is supported in any suitable manner within vault 502 , such as being supported upright on bottom wall 504 . Vault 502 is itself supported in any suitable manner within the interior of a septic tank 505 . Side wall 506 extends vertically upward from bottom wall 504 to bound the vault interior. Side wall 506 is closed except for being open at the top and having a series of holes 508 spaced in succession around the side wall circumference shortly below the open top of the vault. Liquid in septic tank 505 that is above the level of holes 508 spills into the interior of vault 502 where pump/strainer unit 500 is disposed. In use, the interior of vault 502 will typically be completely filled with liquid so that pump/strainer unit 500 is completely immersed in liquid.
Unit 500 comprises an electric pump like one shown in commonly assigned U.S. Pat. No. 6,231,764. A pump/motor sleeve 34 is disposed upright coaxial with and within the interior of a support tube 36 of larger diameter. Both sleeve 34 and tube 36 can be commercial PVC pipe. Tube 36 is closed at the bottom, either by a sealed fit to bottom wall 504 of the vault (as shown), or by a closure (not shown) that is fit to the lower end of the tube in a fully sealed manner. Sleeve 34 and tube 36 are associated by any suitable construction that keeps the lower end of the sleeve open.
Pump/strainer unit 500 comprises a strainer 10 having a walled enclosure 512 that is fit to, and closes, the upper end of support tube 36 . Enclosure 512 has an interior that serves to communicate support tube 36 to the interior of vault 502 . Enclosure 512 comprises a vertical side wall 514 containing a hole 516 covered by a mesh screen 518 .
An electric pump unit 48 comprising an electric motor 48 m and a pump 48 p driven by the motor is disposed coaxially within sleeve 34 . When unit 48 operates, it draws liquid in vault 502 through strainer 10 . The flow path through unit 500 is shown by the arrows. Liquid is strained by screen 518 as it enters the interior of enclosure 512 at hole 516 . It passes through the interior to enter support tube 36 , thence downwardly through the annular space between sleeve 34 and tube 36 , and thence around the lower edge of sleeve 34 where it enters the sleeve. The liquid then flows upward through the sleeve to enter the pump, which will pump the liquid out as effluent through a discharge conduit, or pipe, 49 extending from the pump discharge outlet. As the liquid passes along the exterior of motor 48 m , heat from the motor can transfer to the liquid whereby the liquid provides motor cooling. As the unit is being operated, liquid under pressure is being delivered to a spray nozzle 28 through a supply pipe 50 to clean screen 518 . Because the pumped effluent has been strained by strainer 10 , it may be used to supply spray nozzle 28 by teeing pipe 50 into conduit 49 . The upper end of sleeve 34 is closed to the top horizontal wall 520 of enclosure 512 , and both conduit 49 and pipe 50 pass through, and are sealed to, holes in that wall. Thus, within the liquid in vault 502 , unit 500 is totally enclosed except for the opening to the interior of enclosure 512 through screen 518 .
The liquid drawn from the interior of enclosure 512 is continually replenished by flow through screen 518 . Screen 518 strains the liquid that enters enclosure 512 so that particulate and other material larger than a certain size is prevented from entering the enclosure. In this way the liquid is strained before it ever reaches the pump.
Spray nozzle 28 comprises a spray mechanism like that of U.S. Pat. No. 5,058,806, hereby incorporated by reference. That mechanism is effective to create a spray that is directed outwardly against the inside of screen 518 to dislodge adhering debris from the outside of the screen. The spray washes only a limited area of screen 518 at any given time, but it moves across the screen to eventually wash the entire screen area. The spray motion may be rotary or oscillatory. The screen may be flat or curved. Because a limited zone of the screen is being cleaned at any given time, liquid can be drawn through the remainder of the screen by the pump.
In a specific embodiment, enclosure 512 comprises an upright cylindrical tube that is closed at both top and bottom. Tube 36 is also closed at both ends. A short horizontal tube 513 extends between confronting portions of the side walls of the two vertical tubes just below the closed upper ends of the two tubes. Tube 513 serves to communicate the interior of the tube forming enclosure 512 to the interior of tube 36 .
FIG. 6 shows an embodiment that is like that of FIG. 5 except that vault 502 is not used, and pump/strainer unit 500 is instead disposed directly within septic tank 505 . Like elements in both FIGS. 5 and 6 are identified by the same reference numerals, and so a detailed description of unit 500 will not be repeated in connection with FIG. 6 . When unit 500 is placed directly within septic tank 505 without vault 502 , it is preferable to locate screen 518 in the intermediate zone of liquid in the tank. When vault 502 is used, the vault aids in preventing larger material suspended in liquid from entering the vault.
FIG. 7 shows another embodiment of pump/strainer unit 700 that is disposed within a vault 502 like the one of FIG. 5 . Vault 502 is in turn disposed within a septic tank 505 . Unit 700 comprises a pump like the one described in connection with FIG. 5, but does not use a tube 36 because the associated self-cleaning strainer 10 A communicates to the bottom of sleeve 34 . Sleeve 34 is still disposed upright and is closed at the top so that liquid in the septic tank cannot enter that end.
Strainer 10 A comprises a walled enclosure 512 A having an interior for conveying strained liquid into the lower end of sleeve 34 . At its upper end, the strainer comprises a mesh screen 712 that is cleaned by a spray nozzle 28 disposed interior of the screen. In a specific embodiment, enclosure 512 A comprises an upright cylindrical tube that is closed at the bottom. A short horizontal tube 513 A extends between confronting portions of the side wall of the tube forming enclosure 512 A and the side wall of sleeve 34 .
Nozzle 28 may. be like the one previously described, with either rotary or oscillatory motion of the spray across the screen. The screen may be flat or curved, and it may have a full or partial circumferential extent. FIG. 7 shows a specific example where screen 712 is circular with its upper and lower edges secured to the margins of circular walls 714 , 716 . Holes are present at the centers of walls 714 , 716 . The body of spray nozzle 28 passes through the hole in wall 714 , and a cap 720 that supports nozzle 28 closes the hole. The hole in the center of wall 716 is fit to the upper end of the tube forming enclosure 512 A. The spray emitted from nozzle 28 traverses screen 712 with circumferential motion.
FIG. 8 shows an embodiment that is like that of FIG. 7 except that vault 502 is not used, and pump/strainer unit 700 is instead disposed directly within septic tank 505 . Like elements in both FIGS. 7 and 8 are identified by the same reference numerals, and so a detailed description of unit 700 will not be repeated in connection with FIG. 8 . When unit 700 is placed directly within septic tank 505 without vault 502 , it is preferable to locate screen 712 in the intermediate zone of liquid in the tank.
FIG. 8A shows an example of a septic system that comprises an in-ground septic tank 505 . Tank 505 encloses a rectangular volume into which liquid waste, such as household sewage, is introduced through an inlet pipe 101 . A pump/strainer unit 700 is disposed within tank 505 for drawing liquid from the tank and pumping it out as effluent through a discharge pipe 49 to a drain field. The top of tank 505 is closed by a tank lid, or cover, 104 that contains two access risers 105 , 106 extending upward to above ground level. The risers are cylindrical in shape and are closed at the top by removable caps 107 , 108 . When removed from the risers, caps 107 , 108 allow access to inlet pipe 101 and to pump/strainer unit 700 .
When a new septic tank is being installed, the tank can be set in an excavation with or without pump/strainer unit 700 installed. Before tank lid 104 is placed on the tank and the tank covered with fill, unit 700 can be easily placed into the tank because the top is fully open. After the unit has been placed, a pipe leading from the unit to the drain field can be connected to discharge pipe 49 in any appropriate manner. FIG. 8A shows such a pipe passing through the sidewall of riser 106 , above lid 104 , but below cap 108 . The Figure also shows a float switch tree 111 as part of the unit. The tree may be supported upright from a stand that forms the base of the unit. The switches of the tree control the operation of the electric operated pump to pump out effluent when the level rises to a certain level in the tank and to then shut off the pump once the tank has been pumped out to below a certain level. The switches are at elevations intended to keep strainer 10 A in the intermediate zone of liquid in the tank. FIG. 8 further shows electric connections 113 , 115 to both the tree and the pump motor.
In an existing septic tank installation that has a pump, but lacks the self-cleaning strainer of the present invention, the tank is below ground, and so the only access for retrofitting the existing installation with a self-cleaning strainer 10 A is via riser 106 . The maximum lateral dimension of unit 700 allows it to pass through conventional risers that may have diameters as small as twenty inches. Hence, the inventive unit can retrofit, and be serviced when needed, via the existing riser.
FIG. 9 shows another embodiment where a strainer 910 is associated with a pump vault 905 containing a pump 906 to form a unit 900 . Pump 906 may be a centrifugal type, electric operated pump. Although a septic tank is not shown, unit 900 is disposed in any suitable manner within the tank, such as simply resting on the bottom wall of the tank. Vault 905 comprises a walled enclosure that is closed except for having an entrance opening 907 and an exit opening 908 in a top horizontal wall of the vault. Strainer 910 is disposed in covering relation to entrance opening 907 . Exit opening 908 provides for discharge pipe 911 to pass upward from the discharge outlet of pump 906 to transport pumped effluent out of the tank. A supply pipe 914 is teed into pipe 911 for returning some of the pumped effluent to a spray nozzle 28 that is disposed within the interior of strainer 910 . Strainer 910 comprises a walled enclosure containing a screen 912 . The screen may be flat or curved, and it may have a full or partial circumferential extent. Nozzle 28 may be like the one previously described, with either rotary or oscillatory motion of the spray across the screen. The walled enclosure of strainer 910 fits onto the top wall of vault 905 over entrance opening 907 . The bottom of the walled enclosure is open to expose the enclosure interior to the interior of vault 905 .
FIG. 9 shows a specific example where screen 912 is circular with its upper and lower edges secured to circular edges of the enclosure side wall. Supply pipe 914 passes through the otherwise closed top wall of the enclosure and spray nozzle is attached to and supported from the end of the supply pipe. The spray emitted from nozzle 28 traverses screen 912 with circumferential motion.
FIG. 10 shows another embodiment of pump/strainer unit 1000 that is disposed within a vault 1002 that in turn is disposed within a septic tank 1005 . Unit 1000 comprises a pump 906 and discharge pipe 911 like those described in connection with FIG. 9. A supply pipe 914 is teed into pipe 911 for returning some of the pumped effluent to a spray nozzle 28 that is disposed within the interior of a strainer 1010 that is associated with the pump and vault to form unit 1000 . Strainer 1010 is disposed on the exterior of vault 1002 beneath the bottom horizontal wall of the vault in covering relation to entrance opening 1007 in the bottom wall of the vault. Supply pipe 914 passes through the interior of the vault and entrance opening 1007 to spray nozzle 28 . Strainer 1010 comprises a screen 1012 that may be flat or curved, and that may have a full or partial circumferential extent. Nozzle 28 may be like the one previously described, with either rotary or oscillatory motion of the spray across the screen.
FIG. 10 shows a specific example where screen 1012 is circular with its upper edge configured in any suitable way to close against the bottom wall of the vault. The lower edge of the screen is fit to the margin of a circular wall of the strainer enclosure that closes the bottom of the strainer. The embodiment of FIG. 10 is intended to be suspended in a septic tank to place the strainer in the intermediate zone of liquid in the tank.
FIG. 11 shows an embodiment similar to FIG. 10 except that the screen mounts directly in the side wall of vault 1002 at a level above the bottom wall of the vault. This allows the vault to be mounted on the bottom wall of the septic tank. The screen covers a hole in the vault wall.
In embodiments where a pump/strainer unit is disposed directly in a septic tank, without a pump vault, a float switch tree, like tree 111 in FIG. 8A, may be associated with the pump/strainer unit to operate the pump motor so that the intermediate zone of liquid in the tank is maintained at the level of the mesh strainer screen. In embodiments using a pump vault that has openings 508 near the top of the pump vault, opening that are above the self-cleaning strainer, a switch tree may be external to the pump vault, to keep the intermediate zone in the tank at the same level as openings 508 so that liquid that enters the pump vault from the tank through openings 508 will come from the intermediate zone of liquid in the tank.
In any of the embodiments shown using a spray nozzle 28 , a different type of nozzle may be substituted, with the screen shape possibly being modified to accommodate the different nozzle. For example, the rotary spray arm shown in FIGS. 2-4 may be substituted, in which case, the screen may not extend around the full circumferential extent of the strainer. In any embodiment the spray must have sufficient strength to dislodge debris from the screen, but at the same time, the spray should not be so strong as to excessively disturb the contents of the tank, especially when the outer face of the screen does not face a wall of a pump vault like it does in FIGS. 5 and 7. Hence, in installations like those of FIGS. 6, 8 , 9 , 10 , and 11 , it may be desirable to place a wall of suitable size and shape a short distance from the outer face of the screen, in the same way that wall 346 is associated with the screen in FIG. 3 . While the invention may be practiced in various embodiments, such as those specifically illustrated, the inventive principles also contemplate uses where a self-cleaning strainer is installed in a septic system that is already in use, i.e. retrofitting of an existing septic system. Certain embodiments that have been illustrated and described are especially suited for existing septic tank pumps and vaults.
While a presently preferred embodiment of the invention has been illustrated and described, it should be appreciated that principles of the invention are applicable to other embodiments within the scope of the following claims. | A system for limiting the size of particulate matter entering a septic tank pump contains a strainer that has a straining screen through which the pump draws liquid from the septic tank. A nozzle receives some of the effluent being pumped by the pump and is aimed toward the screen for directing effluent toward the screen to dislodge particulate matter from an area of the screen while the pump draws liquid through the screen. The screen and nozzle are arranged for relative movement so that the area of the screen being acted on by the effluent from the nozzle changes as the pump operates. Various embodiments are disclosed. | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
The present application is a continuation of, and therefore claims benefit under 35 U.S.C. §120 to, U.S. patent application Ser. No. 14/065,217, filed on Oct. 28, 2013, which is a continuation of, and therefore claims benefit under 35 U.S.C. §120 to, U.S. patent application Ser. No. 13/711,271, filed on Dec. 11, 2012, having issued as U.S. Pat. No. 8,567,514 on Oct. 29, 2013, and is a continuation of, and therefore claims benefit under 35 U.S.C. §120 to, U.S. patent application Ser. No. 13/333,251, filed on Dec. 21, 2011, having issued as U.S. Pat. No. 8,347,971 on Jan. 8, 2013. The present application is also a continuation of, and therefore claims benefit under 35 U.S.C. §120 to, U.S. patent application Ser. No. 12/718,888, filed on Mar. 5, 2010, having issued as U.S. Pat. No. 8,082,997 on Dec. 27, 2011, and is a continuation of, and therefore claims benefit under 35 U.S.C. §120 to, U.S. patent application Ser. No. 11/371,742, filed on Mar. 9, 2006, having issued as U.S. Pat. No. 7,703,540 on Apr. 27, 2010. Further, the present application is a continuation in part of, and therefore claims benefit under 35 U.S.C. §120 to, U.S. patent application Ser. No. 10/995,907, filed on Nov. 24, 2004, having issued as U.S. Pat. No. 7,216,716 on May 15, 2007, and is a continuation in part of, and therefore claims benefit under 35 U.S.C. §120 to, U.S. patent application Ser. No. 10/315,617, filed on Dec. 10, 2002, having issued as U.S. Pat. No. 6,920,931 on Jul. 26, 2005. Furthermore, the present application is a continuation in part of, and therefore claims benefit under 35 U.S.C. §120 to, U.S. patent application Ser. No. 10/995,905, filed on Nov. 24, 2004, having issued as U.S. Pat. No. 7,222,677 on May 29, 2007, and is a continuation in part of, and therefore claims benefit under 35 U.S.C. §120 to, U.S. patent application Ser. No. 10/315,617, filed Dec. 10, 2002, having issued as U.S. Pat. No. 6,920,931 on Jul. 26, 2005. Moreover, the present application is a continuation of, and therefore claims benefit under 35 U.S.C. §120 to, U.S. patent application Ser. No. 13/333,166, filed on Dec. 21, 2011, having issued as U.S. Pat. No. 8,267,182 on Sep. 18, 2012. These priority applications are hereby incorporated by reference in their entirety herein.
BACKGROUND OF THE INVENTION
Field of the Invention
This invention involves an apparatus and method for installing pipe and control line in an earthen borehole. Specifically, this invention involves a spider having components that are adapted for being manipulated to facilitate securing of control line to a pipe string as it is being made up and run into a borehole.
Background of the Invention and Related Art
Oil and gas wells may be equipped with control lines for mechanically, electrically, pneumatically, hydraulically or optically linking various downhole devices to the surface. Control lines may be used to receive data from downhole instruments or to operate downhole devices such as valves, switches, sensors, relays or other devices. Control lines may be used to open, close or adjust downhole valves in order to selectively produce or isolate formations at locations deep in the well. A control line may transmit data gathered downhole to the surface or communicate commands to downhole devices to take samples, readings, or to stroke valve. Control lines may comprise electrically conductive wires or cables, optical fibers, or fluid conduits for pneumatically or hydraulically controlling downhole devices or transmitting data.
Control lines are generally of a small diameter relative to the diameter of the pipe string to which they are secured, and are generally between 0.5 and 6 cm in diameter. A plurality of control lines may be aggregated to form an umbilical having a diameter of up to 10 cm or more. Control lines are generally secured along the length of the outer surface of a pipe string, generally parallel to the center axis of the bore of the pipe string. Continuous control lines are secured to the pipe string and installed in the well as joints of pipe are made up into a pipe string and run into a well.
Control lines secured to pipe string are subject to being damaged and being rendered useless if they are pinched or crushed by the pipe slips used to grip and support the pipe string while it is being made up and run into the well. This presents a challenge in securing the control lines to the pipe string as it is made up and run into the borehole. Depending on the diameter, length and pipe thickness, the pipe string may weigh more than four hundred thousand pounds. A pipe-gripping tool-called a spider is required to grip and support the pipe string at or near the rig floor. The spider generally comprises a tapered bowl having a bore with an axis that is generally aligned with the borehole. The pipe string passes through the tapered bowl, and the tapered bowl receives a generally circumferential arrangement of radially inwardly movable slips that surround and engage the pipe string within the tapered bowl. The generally wedge-shaped slips are adapted for engaging the outer curved surface of the pipe string and bearing against the tapered inner surface of the bowl to provide generally radially distributed support in a self-tightening manner.
It is important that the pipe slips in the spider generally uniformly grip and support the pipe string in order to minimize localized stress and loads on the pipe that may crush or damage the pipe string. The radially inwardly disposed gripping surfaces of the slips are concave in order to contact the pipe over a radially large area to minimize localized stresses. When control lines are being secured to the pipe and run into the borehole, it is important to prevent the control lines from being pinched or trapped between the spider slips and the outer surface of the pipe string, or between adjacent slips as they move radially inwardly to grip and support the pipe string. If a control line is trapped between the slips and the pipe string or between two adjacent slips, the control line may be damaged with a resulting loss or impairment of surface control of or communication with, downhole devices or instruments that are linked to other devices or to the surface using control line(s). It is important that control lines be secured to the pipe string in a manner that will prevent control line damage.
One method of installing control lines involves extending the control lines along the portion of the pipe string that is gripped and supported within the tapered bowl of the spider. A control line may be aligned and positioned along the length of the exterior surface of the pipe string to radially coincide with and pass through a gap or recess between adjacent slips. This method may be unsatisfactory where multiple control lines are being secured to the pipe string because more of the circumference of the pipe string is required to accommodate the control lines, leaving less contact circumference for the slips to engage and support the pipe string.
The growing appreciation for the advantages and benefits of controllable downhole tools and devices and for receiving data from downhole instruments has resulted in the development of new tools and methods for installing control lines in a well. One approach involves the use of a table-elevated spider constructed on the rig floor to support the spider and the pipe string, thereby creating and maintaining a clamping zone between the table and the rig floor. This “clamping zone” provides access to a portion of the pipe string beneath the spider for introducing and securing control lines along the length of the pipe string. The control lines are fed to the pipe string at a location underneath the table that supports the spider, secured to the pipe string, and then fed into the borehole along with the pipe string as it is made up and lowered into the borehole. While the table-elevated spider prevents slip damage to control lines at the spider, the legs supporting the table must be strong enough to support the entire pipe string, the spider, and the table, which is a work platform for machines and personnel. The required strength of the legs and the space restrictions of the table present significant expense and safety concerns.
Another approach to securing control lines to a pipe string as it is being made up and run into a well involves a spider adapted for being received in a retainer that can be vertically reciprocated from and to its retracted position within or new the floor of the rig. This invention eliminates the need for an elevated table with legs strong enough to support the spider, table and pipe string. After the weight of the pipe string is transferred to the elevator, the retainer and spider are raised from the floor position to create a temporary clamping zone between the raised spider and the rig floor. The control line may be directed over roller guides or sheaves secured on or adjacent to the retainer that supports the spider so that the control line will conveniently align along the exterior length of the pipe string within the temporary clamping zone. After the control line is secured to the pipe string in the clamping zone, the pipe string and the control line are lowered into the borehole and the retainer and the spider are returned to their original position in or near the rig floor for again receiving and supporting the pipe string while an additional pipe segment is made up into the pipe string.
While vertically reciprocating the spider in this manner eliminates the expense and safety concerns associated with the table-elevated spider, there remains a need to optimize the equipment and the methods for securing control line to a pipe string. What is needed is a method of securing a control line to a pipe string that does not require the repeated movement of the entire spider to establish a clamping zone. What is needed is an apparatus that permits the repeated movement of select components of the spider in order to create a clamping zone for securing control line to the pipe string.
SUMMARY OF THE INVENTION
The present invention utilizes a spider having slips for being received within a tapered bowl of the spider, and a vertically reciprocating control line guide for engaging and then imparting a desired configuration or pathway to a control line. The control line guide rollably or slidably engages a control line, and moves between a retracted position and a raised position. The control line guide remains in a retracted position when the spider engages and supports the pipe string. The retracted position of the control line guide is characterized as having at least a portion of the control line guide beneath the top surface of the tapered bowl of the spider. When the control line guide is in its retracted position, the lowermost point on the control line guide, or the “exit,” is positioned below the bottom of the slips and adjacent to the pipe string. The raised position of the control line guide is characterized as having the control line guide sufficiently raised above the top surface of the tapered bowl of the spider to provide a clamping zone in which the control line is positioned along at least a portion of the pipe siring between the raised control line guide and the rig floor. The clamping zone provides access to the portion of the pipe string and the control line for application of a clamp or fastener for securing the control line to the pipe string.
The spider is adapted for repeated manipulation or removal of one or more components of the spider to create an unobstructed pathway for raising the control line guide from its retracted position to its raised position. In one embodiment, the slips are the spider component that are adapted for being repeatedly unseated from their engaged position within the tapered bowl of the spider and removed from the tapered bowl at least to an extent sufficient to clear a pathway for the control line guide to elevate along a portion of the length of the pipe string near the spider. In this embodiment, the spider may comprise a tapered bowl and a set of three slips that includes a center, manipulated slip and two following slips, each hinged or movably coupled to the manipulated slip. The slips surround, engage and support the pipe string when received in their engaged position within the tapered bowl of the spider. The tapered bowl comprises a slot in which the control line guide moves between its retracted and raised positions. The slot may be positioned to coincide with a gap between adjacent following slips when the set of slips is engaged with the pipe string within the tapered bowl. Optionally, the slot may be positioned generally opposite the manipulated slip, which will generally align the slot between the adjacent following slips. The slips may be upset from their engaged position by application of a lifting force to the manipulated slip, primarily in a vertical direction at first, and the set of slips may be completely or just partially removed from the engaged position within the tapered bowl to clear a pathway above the slot to permit raising of the control line guide.
The control line guide may be raised to create a clamping zone when the weight of the pipe string is supported by the elevator and the set of slips are sufficiently removed from their engaged position to clear a pathway for raising the control line guide. The control line guide may be coupled to a jack or to a winch for vertically raising the control line guide above the slot to create a clamping zone. In one embodiment, the slot in the spider may be closable using a plug in door adapted for being generally vertically received within the slot in an interlocking fashion so that the plug-in door provides added load bearing capacity to the tapered bowl. In one embodiment, the plug-in door may be secured to the same jack that raises and lowers the control line guide. In this embodiment, after the control line guide and the plug-in door are raised to create a clamping zone and the control line is secured to the pipe string, the pipe string and the control line may be lowered into the borehole, and the control line guide and the plug-in door may then be lowered to their retracted and engaged positions, respectively. The slips are then restored to their set position within the tapered bowl to engage and support the pipe string while another pipe segment is threadably coupled to the proximal end of the pipe string. The plug-in door may be interlockably received into a slot that is positioned above a “half door” that resembles a conventional side door of a spider, but occupies only a portion of the full vertical height of the spider. The control line guide may penetrate the wall of the spider between the half door and the plug-in door when in its retracted position so that it may be raised along with the plug-in door to create a clamping zone without opening of the half door.
In another embodiment, the tapered bowl of the spider is adapted for removal from its aligned position with the borehole to clear a pathway for raising a control line guide. In this embodiment, the slips are adapted for being upset from their engaged position within the tapered bowl of the spider, but not necessarily for being completely removed from the tapered bowl. Instead, the tapered bowl comprises a generally vertical slot that allows the tapered bowl to be laterally moved to a remote position away from its aligned position with the borehole when the weight of the pipe string is supported by the elevator. The slot in the tapered bowl of the spider may be closable by a conventional door having interdigitated hinges or by a plug-in door that is generally vertically received in an interlocking fashion to close the slot of the tapered bowl and raised from its seated position to open the slot of the tapered bowl. Opening of the slot of the tapered bowl using a plug-in door or a conventional door, or both, provides for lateral movement of the tapered bowl away from its aligned position with the borehole to clear a pathway for the control line guide. The generally horizontal movement of the tapered bowl and slips to the remote position clears the pathway of the control line guide to allow the control line guide to be raised to create a clamping zone above the rig floor and below the raised control line guide.
After the control line is secured to the pipe string at one or more locations within the clamping zone, the pipe string and control line may be lowered into the borehole and the control line guide may be restored to its retracted position. The tapered bowl is laterally restored to its position aligned with the borehole so that it generally surrounds the pipe string, the door is repositioned to close the tapered bowl, and the slips are received within the tapered bowl to engage and support the pipe string.
In another embodiment of the present invention, the tapered bowl comprises a slot for permitting vertical reciprocation of the control line guide, and the slips are adapted for being secured to a jack and vertically raised from the tapered bowl by raising the jack. A slot in the tapered bowl may permit the spider to be received around and removed from the pipe string. The door for closing the slot in the tapered bowl may be a half door of the conventional interdigitated hinged type or it may be a slidably received plug-in door, or a combination of the two. The slips may be vertically reciprocated using the jack toward and away from the tapered bowl. Slips and/or the plug in door may be reciprocated using the same jack that reciprocates the control line guide through the pathway cleared by removal of the plug-in door. After the weight of the pipe string is transferred to the elevator, the jack is moved into position to engage the slips and the plug-in door. The plug-in door may be coupled to the control line guide so that coupling the jack to the plug-in door also couples the jack to the control line guide. Upon raising the jack, the slips, plug-in door and the control line guide are vertically moved from their positions within the tapered bowl to create a clamping zone between the control line guide and the tapered bowl. After the control line is secured to the pipe string at one or more locations within the clamping zone, the pipe string and the control line are lowered into the borehole, the control line guide and the plug-in door are restored to their retracted positions with at least a portion of the control line guide being beneath the top surface of the tapered bowl, and the slips are received within the tapered bowl to engage and support the weight of the pipe string.
In another embodiment of the present invention, the slot in the tapered bowl is openable to allow the tapered bowl to be laterally removed from its position aligned with the borehole when the weight of the pipe string is supported by the elevator. The slips may remain within the tapered bowl as it is laterally removed from its aligned position with the borehole, or the slips may be securable to a jack that raises the slips to a raised position generally above the tapered bowl before the tapered bowl is moved, and also lowers the slips toward their engaged position within the tapered bowl when the tapered bowl is restored to its aligned position with the borehole. Similarly, the control line guide may be secured to a plug-in door, and the plug-in door may be in turn secured to a jack that raises the control line guide and the plug-in door to a raised position to create a clamping zone between the control line guide and the rig floor. The slips may be secured to the same jack that raises the control line guide and the plug-in door so that the slips are vertically raised away from their engaged position within the tapered bowl as the control line guide is raised to create a clamping zone.
After the control line is secured to the pipe string at one or more locations within the clamping zone, the pipe string and the control line may be lowered into the borehole and the tapered bowl may be restored to its aligned position with the borehole. Once the tapered bowl is restored to its aligned position with the borehole, the control line guide, plug-in door and slips may be lowered by the jack so that the control line guide can be received into its retracted position with at least a portion of the control line guide being beneath the top surface of the tapered bowl, the plug-in door may be vertically slidably received into the slot to strengthen the tapered bowl for supporting the pipe string, and the slips may be received in the tapered bowl to engage and support the pipe string.
In certain embodiments of the present invention, the tapered bowl of the spider is adapted for slidably receiving and surrendering a plug-in door to complete and strengthen the tapered bowl. Unlike the more conventional side door that couples to the tapered bowl with pins inserted through interdigitated hinges disposed on each end of the door, a plug-in door may be vertically slidably received in an interlocking fashion within a slot in the side of the tapered bowl. The plug-in door may comprise a door with a pair of generally vertical and downwardly disposed elongated posts, each coupled at their top end to a support plate and each receivable into a receptacle or port in the tapered bowl. Another type of plug-in door comprises a pair of outwardly disposed opposing T-shaped keys adapted for being vertically slidably received into mating T-shaped slots disposed on either side of the slot of the tapered bowl into which the plug-in door seats.
The control line guide which, depending on the embodiment, may or may not be coupled to a plug-in door, may be shaped to impart a desired pathway to a portion of the control line that is received thereon. The control line guide is adapted to gradually-bead and redirect a portion of the control line into position adjacent to and along the portion of the pipe string that extends from below the raised control line guide and into the borehole. The control line approaches the control line guide from a position radially outwardly from the pipe string. Sheaves, rollers or guides may be used to strategically position and direct the control line to the receiving portion of the control line guide. The control line guide may be shaped or adjustable for accommodating differing control line sizes or approach angles depending on the configuration of the rig, but generally it is preferred to have the control line approach the control line guide from a position lateral to and above the control line guide in order to prevent tripping hazards or obstacles to movement by personnel working on the rig floor around the spider.
A control line guide usable for each of the above-referenced embodiments is adapted for slidably or rollably contacting a portion of the control line that is reeved through the control line guide. The pathway imposed by the control line guide on the control line is contoured to prevent unwanted kinking or excessive localized bending of the control line that might permanently impair the function or capacity of the control line. The control line guide may comprise a series of slides, rollers, guides or combinations of these, secured in a fixed or in an adjustable relationship one to the others. The control line guide may be adapted for continuous feed of a lubricant, coating or adhesive to the exterior jacket of the control line as it passes through or over the control line guide, and the control line guide may be adapted for accommodating instruments for inspection or testing of the control line as it passes through or over the control line guide.
In addition to raising and lowering, the control line guide and other components, machines may also be adapted to manipulate components of the spider to clear a pathway for the vertical reciprocation of the control line guide. For example, after the weight of the pipe string is transferred to the elevator, the slips may be engaged and upset from their set position within the tapered bowl, and then partially lifted and partially removed from their aligned position with the borehole, all using a pneumatically or hydraulically-powered mechanism. A mechanical linkage may be coupled to a latching portion at or near the top of the manipulated slip to displace it initially upwardly and then radially outwardly away from the pipe string thereby causing the following slips to each rotate relative to the manipulated slip to clear the pathway for the vertically reciprocating control line guide. In some embodiments, this movement of the slips also allows passage through the tapered bowl of the clamp that secures the control line to the pipe string. Alternately, a mechanical linkage may be coupled to the manipulated slip to displace it initially upwardly and radially outwardly away from the pipe string to cause each of the following slips to rotate relative to the manipulated slip and to clear a pathway for the withdrawal of the pipe string from the tapered bowl with lateral movement of the tapered bowl away from its position aligned with the borehole. Depending on the embodiment of the invention used, the mechanism used to manipulate the slips may remove the slips completely from the tapered bowl or it may only partially remove the slips from their set position within tapered bowl, depending on the extent to which the slips must be moved. The extent of movement of the slips may be minimal for releasing the pipe string, more for reciprocation of the control line guide, and still more for providing clearance for the control line clamp to pass through the tapered bowl.
For the embodiments of the present invention adapted for removal of the tapered bowl to a remote position and restoration of the tapered bowl back to its position aligned with the borehole, a runway may be adapted for slidably or rollably receiving and supporting the tapered bowl as it moves laterally away from and then back to its position aligned with the pipe string. The runway acts as a support platform for the tapered bowl to facilitate movement to one or more remote positions to clear a pathway for reciprocation of the control line guide. The runway may be selectively radially positionable at two or more positions about the borehole, but is preferably aligned opposite the slot of the tapered bowl.
Machines may be adapted for movement of the tapered bowl, for opening or closing of the side door of the tapered bowl, and for removal or restoring the plug-in door to its position in the slot of the tapered bowl. For example, the embodiments requiring manipulation of the slips and the tapered bowl to clear a pathway for reciprocating the control line guide may require a first linkage for unseating the slips from their engaged position after the weight of the pipe string is transferred to the elevator. If the spider comprises a tapered bowl having a hinged side door, the door must be unlatched and opened to enable removal of the pipe string from the tapered bowl. A sliding latch mechanism may couple to the tapered bowl and move it along the runway adjacent to the borehole to its remote location. After the control line guide is raised to create a clamping zone and the control line is secured, the pipe string and the control line are lowered into the borehole, and the sliding latch mechanism may move the tapered bowl back along the runway to restore the tapered bowl to its position aligned with the borehole, and other mechanisms may restore the side door or plug-in door to close the slot in the tapered bowl, and also to restore the slips to engage and support the pipe string.
The mechanical linkage for moving the tapered bowl along the runway may cooperate with the control line guide such that a position sensor on the mechanical linkage enables the powered jack to begin raising the control line guide only after the tapered bowl reaches a certain distance from the pipe string. Similarly, a tapered bowl position sensor on the control line jack may enable the linkage to begin returning the tapered bowl along the runway towards its aligned position with the borehole when the control line guide has been lowered to a certain position or when it has been returned to its fully retracted position.
In the embodiments of the present invention adapted for vertical displacement of the slips, the slips may be raised using the same or a different jack that raises the control line guide and/or the plug-in door to a raised position. Because the initial movement of the slips from engagement is necessarily up and then radially outwardly away from the pipe string, a jack for raising the slips may be adapted for providing an initial upward unseating movement of the slips, followed by a raising of the slips and/or the control line guide. Similarly, a mechanical linkage may be adapted for providing lateral movement of the slips away from the pipe string. For example, in the embodiment adapted for lateral movement of the slips from the tapered bowl, the slips may be initially raised from their engaged position within the tapered bowl to a vertical position sufficient to clear the top surface of the tapered bowl, and then the slips may be moved radially outwardly away from their aligned position with the borehole.
In the embodiments adapted for removal of both the slips and the tapered bowl from their aligned positions with the borehole, the slips need only be unseated from their engaged position, and then raised to a substantially shorter vertical distance sufficient to disengage them from the pipe string and to permit the following slips to rotate slightly relative to the manipulated slip. This limited movement of the slips suffices to clear the pathway of the control line guide without necessarily displacing the slips to a position above the top surface of the tapered bowl.
In each embodiment of the present invention, after the control line guide is raised and the control line clamp installed to secure the control line to the pipe string the pipe string and the control line may be lowered into the borehole as the control line is fed to the control line guide. The control line guide is retracted, the tapered bowl and the slips restored to their positions aligned with the borehole, the side door and/or plug-in door is restored to close the slot and strengthen the tapered bowl, and the slips are then disposed to their set position in the tapered bowl so that the weight of the pipe string can be transferred to the spider. After a new pipe segment is threadably coupled to the proximal end of the pipe string and torqued to a predetermined torque, the weight of the pipe string is transferred to the elevator and the process is repeated.
“Jack,” as that term is used herein, includes but is not limited to jacks, winches, lifts and other powered devices for generally one-dimensional displacement of an object. A jack may be powered pneumatically, hydraulically, electrically or mechanically, and it may include a rotating screw drive, cylinder, scissor extension, track and pinion or other devices.
“Elevator,” as that term is used herein, includes but is not limited to a side door elevator, an elevator comprising internal or external slips and all other devices used for gripping and supporting a pipe string from above the spider, including those supported by a top drive or draw works.
The terms “comprising,” “including,” and “having,” as used in the claims and specification herein, shall indicate an open group that may include other elements not specified. The term “consisting essentially of,” as used in the claims and specification herein, shall indicate a partially open group that may include other elements not specified, so long as those other elements do not materially alter the basic and novel characteristics of the claimed invention.
The terms “a,” “an,” and the singular forms of words shall be taken to include the plural form of the same words, such that the terms mean that one or more of something is provided. For example, the phrase “an apparatus having a drive motor” should be read to describe an apparatus having one or more drive motors. The term “one” or “single” shall be used to indicate that one and only one of something is intended. Similarly, other specific integer values, such as “two,” are used when a specific number of things is intended.
The terms “preferably,” “preferred,” “prefer,” “optionally,” “may,” and similar terms are used in the specification to indicate that an item, condition or step being referred to is an optional (not required) feature of the invention.
While a preferred form of the present invention has been described herein, various modifications of the apparatus and method of the invention may be made without departing from the spirit and scope of the invention, which is more fully defined in the following claims.
The foregoing, as well as other, objects, features, and advantages of the present invention will be more fully appreciated and understood by reference to the following drawings, specification and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of one embodiment of a spider of the present invention in its position aligned with the borehole and engaging the pipe string with a control line guide in its retracted position with at least a portion of the control line guide beneath the bottom of the slips within the spider.
FIG. 2 is a perspective view of the embodiment shown in FIG. 1 with the slips disengaged from the pipe string but remaining within the tapered bowl of the spider, and the side door of the tapered bowl opened to open a slot in the side of the tapered bowl to permit the movement of the tapered bowl laterally away from the pipe string along a runway.
FIG. 3 is a partial cross-section perspective view of one embodiment of the present invention showing the cross-section of the rotary adapter for supporting the spider within the rig floor and for accommodating the control line guide in its retracted position within the slot of the rotary adapter. The tapered bowl is shown in its remote position laterally removed from the pipe string along a supporting runway.
FIG. 4 is a perspective view of one embodiment of the present invention with the tapered bowl of the spider in its remote position and the control line guide elevated to its raised position using a hydraulically telescoping jack to raise the control line guide and position a portion of the control line along a portion of the pipe string to create a clamping zone.
FIG. 5 is a perspective view of an embodiment of the present invention with the slips laterally removed from the tapered bowl along a runway and a plug-in door and control line guide coupled to a hydraulically telescoping jack. The tapered bowl has a radial slot for receiving the plug-in door, and through which the control line guide reciprocates between its retracted and its raised position.
FIG. 6 is a perspective view of the embodiment shown in FIG. 5 after the slips have been partially returned to their engaged position within the tapered bowl and the control line guide and the plug-in door both restored to their retracted and closed positions, respectively, with at least a portion of the control line guide beneath the top surface of the tapered bowl.
FIG. 7 is a perspective view of an embodiment of the present invention with the tapered bowl having a plug-in door received into a slot through which the control line guide passes when it is raised from its retracted position, and also having a pair of opposed hangers for pivotably engaging and latching to the slips. The control line guide is coupled to the plug-in door that also supports the pivoting hangers so that the slips can be raised above the tapered bowl using the same jack that raises the control line guide and the plug-in door.
FIG. 8 is a perspective view of the embodiment of the present invention having an alternative apparatus for raising the control line guide, plug-in door and the slips along a portion of the pipe string above the tapered bowl. The control line guide and plug-in door are raised using a winch cable coupled to a lift plate, and the path of the control line guide, plug-in door and slips conforms to the pathway dictated by the structural guide positioned adjacent to the pipe string prior to the onset of running the control line.
FIG. 9 is a perspective view of an embodiment of the present invention having an alliterative apparatus for raising the control line guide, plug-in door and slips above the tapered bowl. The control line guide is coupled to a plate that is raised using a scissor-lift jack. The scissor-lift jacks supports a latch that couples to the slips to raise the slips from the tapered bowl, and the scissor-lift jack supports an opposed pair of opposed supports that pivot to engage and support the control line guide and plug-in door.
FIG. 10 is a perspective view of the embodiment of FIG. 9 with the slips, plug-in door and control line guide elevated to the raised position to align a portion of the control line along a portion of the pipe siring to create a clamping zone.
FIG. 11A is a side view of the embodiment of the present invention having a truncated interdigitated door below a space for penetration of the control line guide below a plug-in door received into the tapered bowl of a spider.
FIG. 11B is a top offset cross-section view of the embodiment of the present invention shown in FIG. 11A showing the plug-in door received in an interlocking fashion into the tapered bowl to close the slot, and the top of the truncated interdigitated door below the plug-in door.
FIG. 12 is a top view of a plug-in door that is adapted for being received into the tapered bowl shown in FIGS. 11A and 11B . The plug-in door is coupled to and supports the control line guide. A control line is shown reeved through the control line guide.
FIG. 13 is a front elevation view of an embodiment of a plug-in door and control line guide of the present invention having a control line reeved through the control line guide.
DETAILED DESCRIPTION
FIG. 1 is a perspective view of one embodiment of a spider 12 of the present invention comprising a tapered bowl 20 in its position aligned with the borehole 10 and engaging the pipe string 30 just below a pipe joint 32 . The control line guide 80 is shown in its retracted position with at least a portion of the control line guide beneath the top surface 21 of the tapered bowl. The tapered bowl 20 comprises a door 24 that is openable to receive the pipe string 30 into the bore 34 of the tapered bowl 20 . The door 24 shown in FIG. 1 is a conventional door having hinged connections to the tapered bowl at each end. A rotary adapter 22 supports the spider and accommodates the control line guide 80 in a slot 23 when the control line guide is in its retracted position. Adjacent to the spider 12 is a runway 28 releasably coupled to the rotary adapter 22 . The runway is adapted for receiving and supporting the tapered bowl 20 when it is moved laterally away from the pipe string 30 to a remote position (see FIG. 2 ). The tapered bowl 20 receives and cooperates with a set of slips (not shown in FIG. 1 ) to wedge between the pipe string and the tapered surface of the bowl to grip and support the pipe string 30 .
The control line guide 80 comprises a plurality of generally spaced-apart rollers 82 , each having a generally horizontal axis of rotation, and each retained in a generally fixed relationship relative to the other rollers. The control line guide receives the control line 92 from, or surrenders the control line to, a spool (not shown). The control line 92 may be reeved over sheaves (not shown) to strategically direct the control line to the control line guide from above or, when the control line is being removed from the borehole, to strategically direct the control line to a spool (not shown) for storage.
The tapered bowl 20 comprises a door 24 received to close a slot 25 . The door 24 is secured to the tapered bowl 20 with a pair of hinges 36 adapted for receiving a pair of pins 27 . Removal of either closure pin 27 enables the door to hingedly swing open for removal of the tapered bowl 20 from its aligned position with the borehole (as shown in FIG. 2 ). Removal of the pin requires that the weight of the pipe string first be transferred to the elevator (not shown).
A runway 28 is positioned adjacent to the rotary adapted 22 for slidably or rollably supporting the tapered bowl when the door 24 is opened and the tapered bowl is moved laterally away from the pipe string 30 (as shown in FIG. 2 ). The runway is angularly positionable about the rotary adapter 22 so that the runway may align with the movement of the tapered bowl that will be opposite the door 24 , but may also allow movement of the tapered bowl 20 about the rotary adapter 22 while the tapered bowl is stored in its remote position on the runway.
FIG. 2 is a perspective view of the embodiment of the present invention shown in FIG. 1 with slips 60 , 62 removed from the tapered bowl 20 of the spider 12 and the door 24 opened at one hinge 26 to open slot 25 of the tapered bowl 20 to facilitate movement of the tapered bowl laterally away from the pipe string 30 to its remote position on the runway 28 . The slips shown in FIG. 2 are a set of three slips consisting of one manipulated slip 60 hinged through hinges 61 disposed on opposing sides of slip 60 to following slips 62 . The runway may contain a slot 29 through which a mechanism (not shown) may engage and pull or push the tapered bowl 20 along the runway 28 . Lateral movement of the tapered bowl 20 away from the pipe string 30 to its remote position on the runway 28 reveals the lift plate 84 . The lift plate 84 is adapted for supporting the control line guide 80 , for covering the slot in the rotary adapter (see FIG. 1 , element 23 ) in the rotary adapter 22 and for evenly distributing the load from the tapered bowl 20 to the rotary adapter 22 when the tapered bowl is in its position aligned with the borehole 10 (see FIG. 1 ).
FIG. 3 is a partial cross-section perspective view of the embodiment shown in FIG. 2 showing the cross-section of the rotary adapter 22 for supporting the spider 12 engaging the rig floor 8 and for accommodating the control line guide in its retracted position within the slot of the rotary adapter. The tapered bowl 20 is shown supported in its remote position on the runway 28 . The slips 60 , 62 are shown raised from their position within the tapered bowl to facilitate removal of the tapered bowl from its position aligned with the borehole 10 on the rotary adapter 22 . The slot 23 of the rotary adapter accommodates the control line guide 80 in its retracted position. Guide supports 83 couple the control line guide 80 to the lift plate 83 . This figure shows how control line 92 is reeved through the control line guide 80 which is shown in section view. In the embodiment of the control line guide shown in FIG. 3 , the control line 92 rolls on the radially outwardly and bottom portions of the top set of rollers 82 located above and radially outwardly from the guide support 83 , then the control line 92 reeves between the upper and lower sets of rollers adjacent to the guide supports 83 , and then it rolls on the radially inwardly and upwardly disposed portions of the lower set of rollers 82 , from which it extends along the length of a portion of the pipe string 30 and down into the borehole 10 .
FIG. 4 is a perspective view of the embodiment of the present invention shown in FIGS. 2 and 3 with the tapered bowl 20 with the side door 24 opened to permit removal of the tapered bowl to its remote position on the runway 28 . The slips 60 , 62 are shown remaining within the tapered bowl but raised from their engaged and seated position within the tapered bowl to permit removal of the pipe string. The control line guide 80 is raised to its raised position using a hydraulically telescoping jack 86 that is coupled at its traveling end to the lift plate 84 . The lift plate is, in turn, coupled to the guide supports 83 that pivotally support the control line guide 80 there under. A portion of the control line 92 is shown positioned by the raising of the control line guide 80 along the length of the pipe string 30 to create a clamping zone 100 beneath the control line guide and above the rotary adapter 22 .
FIG. 5 is a perspective view of alternate embodiment of the present invention with the tapered bowl 20 of the spider having a slot 25 adapted to receive a plug-in door 81 . The plug-in door comprises the lift plate 84 and the downwardly protruding inserts 84 A that are received into vertically aligned receptacles 84 B disposed on each side of the slot 25 in the tapered bowl 20 . In this embodiment, the tapered bowl 20 is shown recessed into the rig floor 8 , and the lower portion of the slot 25 of the tapered bowl 20 is closed using a truncated side door 24 A which, when closed, is disposed in the slot 25 generally below the received position (see FIG. 6 ) of the plug-in door 81 .
The plug-in door 81 is coupled to the traveling end of the hydraulically powered telescoping jack legs 86 , and the control line guide 80 is pivotally supported beneath the lift plate 84 using support links 82 . The inserts 84 A of the plug-in door are vertically aligned with the receptacles 84 B in the tapered-bowl so that the inserts are received into the receptacles upon retraction of the hydraulically telescoping jack legs 86 and lowering of the plug-in door 81 and the control line guide 80 . FIG. 6 is a perspective view of the embodiment shown in FIG. 5 with the control line guide 80 restored to its retracted position with at least a portion of the control line guide beneath the top surface of the tapered bowl 20 . The slips 60 , 62 are shown restored to the tapered bowl 20 aligned with the borehole but retaining above their engaged position within the tapered bowl 20 .
As shown in FIG. 6 , the inserts 84 A of the plug-in door 81 are received into the receptacles 84 B, the control line guide is received into the slot 25 above the truncated side door 24 A and below the seated plug-in door 81 . The arrangement of the plug-in door 81 and the truncated side door 24 A, with a space there between for accommodating the control line guide 80 , provides for convenient removal and reintroduction of the plug-in door 81 from and to the tapered bowl 20 for unseating and reseating, respectively, with reciprocating motion of the control line guide as controlled by the jack 86 . Removal of the plug-in door 81 upon raising of the control line guide 80 from the slot 25 significantly decreases the load bearing capacity of the tapered bowl even though the truncated side door 24 A remains in position to close the lower portion of the slot. The load bearing capacity of the tapered bowl 20 is significantly increased when the plug-in door 81 is slidably vertically received into the slot 25 . The plug-in door provides enhanced hoop strength to the tapered bowl to resist the spreading force on the bowl when the slips engage and support the pipe string.
The slips 60 , 62 are adapted for being removed from their engaged position within the tapered bowl 20 to a remote position as shown in FIG. 5 . Like the tapered bowl of FIGS. 3 and 4 , the slips can be adapted for powered movement to and from the borehole along the runway. The tapered bowl 20 of the embodiment shown in FIGS. 5 and 6 is adapted for remaining stationary in its position aligned with the borehole when the control line guide 80 and plug-in door 81 are unseated and raised above the slot 25 using the telescoping jack legs 86 to create a clamping zone 100 . Machines or rig personnel can access the portion of the pipe string 30 and control line 92 within the clamping zone shown in FIG. 5 to secure the control line to the pipe string using a clamp 34 . After the elevator (not shown) is used to lower the pipe string and the control line secured thereto into the borehole as shown in FIG. 6 , refraction of the jacks (see FIG. 5 , element 86 ) returns the control line guide 80 and the plug-in door 81 to their retracted and received positions, respectively, after one or more clamps are used to secure the control line to the pipe string in the clamping zone 100 .
FIG. 7 is a perspective view of an alternate embodiment of the present invention with the tapered bowl 20 having a slot 25 for receiving the plug-in door 81 and the control line guide 80 in their seated and retracted positions, respectively. The control line guide 80 is shown fitted with a pair of pivoting slip hangers 63 for rotating and engaging the slips 60 , 62 . The slip hangers 63 each have one or more latches 63 A for engaging one or more lift ears 63 B on the slips 60 , 62 . Rotating the slip hangers 63 to engage the lift ears 63 B with the latches 63 A couples the slips to the lift plate 84 so that the slips can be lifted from the tapered bowl using the hydraulically telescoping jacks legs 86 (see FIG. 5 ) used to raise the plug-in door 81 and the control line guide 80 from the slot 25 .
FIG. 8 is a perspective view of an alternate embodiment of the present invention having an alternative apparatus for raising the plug-in door 81 and the control line guide 80 from the slot of the tapered bowl 20 to create a clamping zone 100 . Like the embodiments shown in FIGS. 5-7 , the embodiment shown in FIG. 8 comprises a tapered bowl 20 having a slot 25 for receiving the plug-in door 81 and the control line guide 80 when the plug-indoor and the control line guide are in their seated and retracted positions, respectively. FIG. 8 shows an apparatus using a winch instead of a jack to raise the plug-in door, control line guide and slips from the tapered bowl to an elevated position to establish a clamping zone. The sliding lift plate 75 is coupled to the lift cable 94 and pivotally supports a pair of slip hangers 78 for rotatably engaging the manipulated slip 60 to facilitate lifting the slips 60 , 62 from the tapered bowl 20 . The lift cable 94 is secured to a winch (not shown) and can be reeled in to raise and unreeled to lower the sliding lift plate 75 . A pair of opposed hangers 78 are coupled to the lift plate at a pivot 78 A and pivot to engage the manipulated slip 60 to couple the slips 60 , 62 to the lift plate.
The pathway for raising the plug-in door 81 , the control line guide 80 and the slips 60 , 62 from the tapered bowl 20 is determined by the A-frame 70 . The A-frame 70 comprises a pair of generally vertical rails 72 , each slidably receiving a pair of sleeves 73 each coupled to the lift plate 75 . The lift plate 75 is coupled to a winch cable 94 that raises the lift plate 75 , the control line guide 80 and the slips 60 , 62 to a raised position. Upon actuation of the winch (not shown), the sleeves 73 slide along the vertical length of the rails 72 , and the vertical path of the plug-in door 81 and control line guide 80 conforms to the pathway provided by the sliding movement of the sleeves 73 on the rails 72 positioned adjacent to the pipe string 30 . After the winch is actuated to raise the plug-in door and control-line guide to their raised position to create the clamping zone 100 , clamps (not shown) may be applied to secure the control line 92 to the pipe string 30 . After the pipe string and control line am lowered into the borehole, the winch rotation is reversed to lower the control line guide back to its retracted position through the slot of the tapered bowl. The A-frame 70 may be rollably removable from the vicinity of the borehole on a set of wheels 76 when control line is not being run into the well.
FIG. 9 is a perspective view of an alternative embodiment of the present invention having an alternative apparatus for raising the plug-in door, control line guide 80 and slips 60 , 62 to their raised position above the tapered bowl 20 . Like the embodiments shown in FIGS. 5-8 , this embodiment comprises a tapered bowl 20 with a slot 25 for receiving the control line guide 80 and a plug-in door 81 . The slips 60 , 62 are adapted for being repetitively removed from the tapered bowl 20 each time the control line guide 80 and the plug-in door 81 are raised to create a clamping zone for securing a control line 92 to the pipe string 30 .
FIG. 9 shows the control line guide 80 , the plug-in door 81 , and a scissor-lift jack 70 in the retracted position, with the control line guide 80 and the plug-in door 81 received within the slot 25 of the tapered bowl 20 . The control line guide 80 and plug-in door 81 are raised using the scissor-lift jack 70 . The scissor-lift jack 70 supports a lift plate 74 that is coupled through a slip bracket 75 to the slips 60 , 62 to support and to vertically raise the slips from the tapered bowl 20 as the control line guide 80 and the plug-in door 81 are raised using the scissor-lift jack 70 .
FIG. 10 shows the embodiment of FIG. 9 with the control line guide 80 , the plug-in door 81 and the slips 60 , 62 raised above the tapered bowl 20 using the scissor-lift jack 70 . The drivers for operating the scissor-jack may be coupled to the scissor-jack from beneath the rig floor 8 , and may include a hydraulic or pneumatic cylinder, a screw jack, or electric motor driver, so long as the driver is adapted for forcibly increasing (to raise) or decreasing (to lower) the distance between two adjacent sliding ends 72 of the scissor legs 71 of the scissor-lift.
A pair of opposing plug-in door supports 85 are coupled to and extend outwardly from lift plate 74 to pivotably engage and couple to the plug-in door 81 which supports the control line guide 80 . The plug-in door supports 85 are rotatable about pivots 85 A to permit the generally arcuate plug-in door supports to substantially surround the pipe string 30 and engage support and raise the plug-in door 81 and the attached control line guide 80 to position a portion of the control line 92 along the pipe string in the clamping zone 100 .
FIGS. 11A, 11B, 12 and 13 show more detail relating to one embodiment of the plug-in door 81 used with the embodiments shown in FIGS. 8-10 . FIG. 11A shows a side view of the embodiment of the present invention having a truncated interdigitated door 24 A to close the lower portion of the slot 25 in the tapered bowl 20 vertically below a space for accommodating the control line guide, that space being vertically below a plug-in door 81 received into the upper portion of the slot 25 of the tapered bowl 20 to close the slot. FIG. 11B is a top view of the slot of the embodiment of the tapered bowl of the present invention shown in FIG. 11A . The tapered bowl 20 has a slot 25 adapted for receiving the plug-in door 81 (see FIG. 12 ). The slot 25 extends only a portion of the way downwardly from the top surface 21 of the tapered bowl 20 and is adapted to receive the plug-in door and the control line guide (not shown) so that, when the plug-in door is slidably received into the slot 25 to form a continuous wall perimeter around the top portion of the tapered bowl 20 , the control line 92 and the control line guide 80 through which the control line 92 is reeved penetrates the wall of the tapered bowl through a portion of the slot that remains beneath the received plug-in door.
The tapered bowl 20 further comprises a pair of generally opposed T-slots 102 A and 102 B disposed on opposite sides of the slot 25 for receiving a pair of generally T-shaped keys (see FIG. 12 ) to circumferentially interlock the plug-in door. This structure provides enhanced hoop strength to the tapered bowl 20 when the plug-in door 81 is received. The tapered bowl may comprise a pair of opposed alignment recesses 103 A and 103 B disposed on opposing sides of slot 25 for receiving a pair of alignment wings 86 A, 86 B (see FIG. 12 ) on the plug-in door. The plug-in door is adapted for being received into a pair of slots 105 A and 105 B that are secured to the tapered bowl on opposing sides of the slot 25 . This structure distribute the load across the plug-in door when the tapered bowl receives the slips to engage and support the pipe string.
The slot 25 that receives the plug-in door (see FIG. 12 ) and the control line guide 80 (see FIG. 12 ) also receives a truncated side door 24 A to close the lower portion of the tapered bowl. The truncated side door 24 A is a conventional hinged door for opening to permit removal of the tapered bowl to its remote position away from the pipe string (not shown).
FIG. 12 is a top view of one embodiment of the plug-in door 81 and the control line guide 80 adapted for being received into the slot 25 of the tapered bowl 20 of FIGS. 11A and 11B . The plug-in door 81 is coupled to the control line guide 80 through a pair of guide supports 83 (see FIG. 4 ). The plug-in door 81 comprises a pair of generally opposed T-shaped keys 101 A and 101 B for being received within the T-slots 102 A and 102 B (see FIG. 11B ) to interlock the plug-in door into the tapered bowl. The T-shaped keys are adapted for being slidably vertically received into the T-shaped slots of the tapered bowl to provide enhanced hoop strength to the top portion of the tapered bowl when the slips are received into the bore of the tapered bowl to engage and support a pipe string. Similarly, the generally inwardly curved alignment wings 86 A, 86 B are received within the alignment recesses 103 A, 103 B of the tapered bowl (see FIG. 11B ).
A variety of interlocking configurations can be utilized for slidably and vertically receiving the plug-in door 81 to circumferentially interlock with the tapered bowl 20 to provide enhanced hoop strength to the tapered bowl. The T-slotted plug-in door 81 shown in FIG. 12 and the downwardly disposed insert plug-in door shown in FIG. 5 are two examples of such doors, but any door that is slidably and vertically received into a mating position with the tapered bowl is within the scope of this invention.
As shown in FIGS. 12 and 13 , the control line 92 is reeved through the rollers 82 of the control line guide 80 as shown in FIG. 12 , that is, the control line 92 rides generally along the radially outwardly and downwardly disposed portions of the rollers 82 that lie radially outside the wall of the tapered bowl when the control line guide is received within the slot 25 of the tapered bowl. After passing between the roller supports 89 A and 89 B, the control line 92 rides generally along the radially inwardly and upwardly disposed portions of the rollers 82 that lie radially within the wall of the tapered bowl 80 . This relationship between the control line 92 and the rollers 82 is also shown in FIG. 13 , a side frontal view of the plug-in door 81 and the control line guide 80 . FIG. 13 shows the rollers 82 divided into a top set 82 A and a bottom set 82 B, the top set for contacting the control line 92 generally along the radially outwardly and downwardly disposed portions of the rollers 82 that lie radially outside the wall of the tapered bowl, and the bottom set 82 B for contacting the control line 92 generally along the radially inwardly and upwardly disposed portions of the rollers 82 that lie radially within the wall of the tapered bowl 80 .
While a preferred form of the present invention has been described herein, various modifications of the apparatus and method of the invention may be made without departing from the spirit and scope of the invention, which is more fully defined in the following claims. | A method and apparatus are provided for installing control lines and pipe into a well. The pipe-holding spider that is normally mounted on the rig floor is adapted for easy disassembly and reassembly when the pipe slips within the spider are not engaged with the outer surface of the pipe string so that upon disassembly, a control line guide becomes vertically movable. The control line guide is adapted for being controllably elevated to a distance above the rig floor, thereby providing personnel access to a portion of the length of the pipe string below the elevated control line guide and above the rig floor for securing control line to the pipe string using a fastener. | 4 |
The present invention relates generally to novel compositions possessing anti-neoplastic disease activity and to methods for preparing and using the same. More particularly, the invention provides two structurally related hexapeptide plant tissue isolates, as well as procedures for obtaining the isolates individually, and as mixtures with each other in pure form. Also provided are novel therapeutic methods for the treatment of neoplastic diseases in animals and novel pharmaceutical compositions suitable for use in such treatment methods.
Incorporated by reference herein is the disclosure of the activities of applicant and his co-workers appearing in the Journal of the American Chemical Society, 99, pp. 8040-8044 (1977).
BRIEF SUMMARY
Provided by the invention are the structurally related hexapeptides, bouvardin and deoxybouvardin, having the respective formulae Ia and Ib set out below. ##STR1## Ia, R=OH Ib, R=H
Pure bouvardin and deoxybouvardin are isolated from Bouvardia ternifolia tissue according to a method comprising forming a crude, isopropyl ether-insoluble precipitate of the plant tissue following serial solvent extraction with methanol, acetonitrile, and dichloromethane. Bouvardin and deoxybouvardin are isolated from the crude precipitate and are separated from each other by chromatographic techniques.
The therapeutic methods of the invention comprise administration of from about 0.01 to about 10.0 mg/kg of the compounds to animals, subject to a neoplastic diseases including, e.g., lymphocytic leukemia, melanotic melanoma and adenocarcinoma. Pharmaceutical compositions according to the invention incorporate therapeutically effective amounts of bouvardin or deoxybouvardin in combination with a pharmaceutically acceptable carrier.
Further aspects of the present invention will become apparent upon consideration of the following detailed description.
DETAILED DESCRIPTION
The following example relates to the isolation of bouvardin and deoxybouvardin from tissue of Bouvardia ternifolia, a plant known in the Southwest U.S. and in Mexico by the common names "trompetilla", "tlacoxochitl", and "mirto".
EXAMPLE 1
The dry stems, leaves and flowers of Bouvardia ternifolia are ground in a Wiley mill and stored at -10° C. prior to extraction. In a typical procedure, 12 kg of the ground material is twice extracted for 24 hours with 60 liter aliquots of methanol with the use of a mechanical stirrer. The combined, filtered methanol extracts are concentrated in air to about 2 liters, diluted with an equal volume of a water-methanol mixture (95:5 v/v) and filtered. The filtrate is evaporated to dryness in air and thoroughly extracted three times with 2 liter aliquots of acetonitrile. The acetonitrile extract is evaporated in air to a semi-solid state, dissolved in methanol and taken to dryness under vacuum. The resulting residue (generally about 90 g) is extracted four times for two hours with stirring in 1.5 liter aliquots of dichloromethane, filtered, and evaporated in vacuo. The residue (about 19.1 g) is dissolved in a minimum of methanol and isopropyl ether is added until precipitation ceases. This mixture is allowed to stand overnight in the refrigerator (3° C.) and then filtered by decantation. The precipitate is stirred for one half hour with isopropyl ether, filtered, washed with a small amount of isopropyl ether, and vacuum dried. This provides about 6.3 g of dry, green-brown precipitate.
The crude precipitate is subjected to chromatographic separation to provide isolates of pure bouvardin and pure deoxybouvardin. According to one procedure, the 6.3 g of green-brown precipitate is first chromatographed over a column (180 g) of silica gel 60 (PF254 E. Merck). The column is eluted with hexane-dichloromethane-methanol (25:22:3, v/v/v) and fractions are combined which are similar by thin layer chromatography. The KB-active (see, infra) fraction (1.0 g) is then subjected to two consecutive preparative thick layer chromatographies, developing with hexanedichloromethane-methanol (20:27:3, v/v/v; 3 developments) and then with dichloromethane-methanol (94:6, v/v; 2 developments) for a second preparative chromatographic separation. The KB-active fraction from the first preparative separation is used for the second one. These preparative thick layer chromatographies, after decolorization, result in a colorless, amorphous mixture containing largely bouvardin (formula I, above) and deoxybouvardin (formula Ib). Separation of the two materials is achieved by preparative thin layer chromatography, the developing solvent being ether-ethyl acetate-methanol (15:35:2, v/v/v; 2 developments).
The lower R f material is deoxybouvardin (52.5 mg), obtained as a colorless powder, mp 257°-40° C., [α] D 25 -138° (c 0.7 CHCl 3 ), ms 756 (parent). Bouvardin (121.3 mg) is successfully crystallized from methanol-dicholormethane to give colorless needles, mp 254°-5° C., [α] D 25 -181° (c 1.0, CHCl 3 ), ms 772 (parent. A bouvardin impurity (showing a methyl doublet in the 'H nmr spectrum) is removed by recrystallization from methanol.
An alternative procedure, suitable for large scale isolations of bouvardin alone, may involve successive column chromatographies, as follows. A first silica gel 60 (30:1) treatment column is eluted with hexane-dichloromethane-methanol (20:27:3). The concentrated fraction of bouvardin and deoxybouvardin and other impurities is then chromatographed on another silica gel 50 (50:1) column eluted with ether-ethylacetate-methanol (15:35:2). The fractions containing bouvardin are decolorized with activated charcoal and chromatographed on Al 2 O 3 (50:1) to remove methylbouvardin. The eluent is hexane-dichloromethane-methanol (20:28.5:1.5). The fractions containing bouvardin are combined and evaporated under vacuum. Bouvardin is crystallized from methanol, removed by filtration and dried under vacuum over calcium chloride for forty-eight hours.
The isolative methods of the present invention are thus seen to include the step of preparing a crude, isopropyl ether-insoluble precipitate of bouvardin and deoxybouvardin following solvent extraction of plant tissue. This step is followed by chromatographic separation of a mixture of the two substances from proteinaceous and nonproteinaceous impurities in the precipitate. Finally, bouvardin and deoxybouvardin are chromatographically separated from each other to provide pure isolates. The term "pure" as herein applied to bouvardin and deoxybouvardin shall designate that the compounds or mixture thereof with each other are more than 90 percent free of all materials naturally associated therewith within plant tissue of Bouvardia ternifolia.
The anti-neoplastic utility of bouvardin, deoxybouvardin, and mixtures thereof is demonstrated by the results obtained in standardized "PS", "Bl" and "KB" test systems propounded by the Drug Evaluation Branch, Drug Research and Development, Chemotherapy, National Cancer Institutes as performed by four independent screening labs--Hazelton Laboratories (TRW, Inc.) Vienna, Va; Batelle Memorial Institute, Columbus, Ohio; Southern Research Institute, Birmingham, Ala; and, IIT Research Institute, Chicago, Ill.
The in vivo "PS" tests were carried out on mice according to "Lymphocytic Leukemia P388--Protocol 1.200", published in Cancer Chemotherapy Reports, Part 3, Vol. 3, No. 2, page 9, (September 1972) with results reported in terms of percent survivals of test versus control animals (%T/C). According to the protocol evaluation procedures, a T/C value ≦85% indicates a toxic test, while a T/C value ≦125% demonstrates antitumor activity.
The in vivo "Bl" were carried out on mice according to "Melanotic Melanoma B 16--Protocol 1.300" (id., p. 11) with reporting and evaluation procedures identical to those of the "PS" test.
The in vitro "KB" tests were carried out according to "Cell Culture Screen KB--Protocol 1.600" (id., p. 17) using cells of human adenocarcinoma of the nasopharynx. Test results are expressed as the dose that inhibits cell growth to 50% of control growth by 3 days after drug addition. According to protocol evaluation criteria for pure compounds, anti-tumor activity is demonstrated by an ED 50≦4 μg/ml.
In the "PS" test, bouvardin isolated according to Example 1 exhibited activities of from 135 to 217% T/C at dose levels ranging from 0.02 to 2.0 mg/kg. Table I, below, summarizes the ranges of % T/C values obtained in approximately two hundred "PS" tests. A single value for a given dosage represents either a single test at that level or multiple tests with identical results.
TABLE I______________________________________DOSE RANGE OF % T/C______________________________________2.00 167 to 2051.00 148 to 2170.50 135 to 1860.25 161 to 1880.16 1580.11 150 to 1640.07 1390.04 134______________________________________
In approximately seventy replications of the "l" test, bouvardin exhibited activites in the range of 134-152% T/C at doses varying from 0.12 to 2.0 mg/kg. In approximately ten replications of the "KB" test, bouvardin exhibited an average ED 50 of about 4.3×10 -7 μg/L.
Multiple testings of deoxybouvardin showed "PS" test activities of 142-216% T/C at 0.04 to 2.0 mg/kg doses and "Bl" test activities of 133-175% T/C at 0.25 to 8.0 mg/kg doses. The Ed 50 of deoxybouvardin in the "KB" test system averaged 1.9×10 -8 μg/L.
Mixtures of pure deoxybouvardin and pure bouvardin obtained according to Example 1 and not subjected to chromatographic separation from each other were also tested in the "PS", "Bl", and "KB" protocols. "PS" activity for these "natural" mixtures was 132-257% T/C at dosages of 0.12 to 2.9 mg/kg. "Bl" activity was 132-167% T/C at dosages of 0.12 to 2.0 mg/kg. "KB" test activity for the mixtures averaged less than 10 -2 μg/L.
According to the therapeutic methods of the invention, bouvardin or deoxybouvardin (or mixtures thereof) is administered to animals, subject to a neoplastic disease state (e.g., lymphocytic leukemia, melanotic melanoma, and adenocarcinoma) in a dosage form of from about 0.1 to about 10.0 mg/kg.
Because pure bouvardin, pure deoxybouvardin and mixtures thereof are partially soluble in water, a wide variety of pharmaceutically acceptable aqueous- and non-aqueous-based diluents, adjuvants and carriers may be employed in preparing the pharmaceutical compositions of the invention wherein the compounds or mixtures provide the active ingredient. As one example, the "PS" and "Bl" tests noted above involved subcutaneous administration of the test compounds in simple water solution forms. It is expected that water solutions of bouvardin and deoxybouvardin would ordinarily be stabilized by addition of antioxidant substances.
Compositions of the invention may be employed according to the above-noted methods by means of a variety of administrative routes, including oral and parenteral administration. Preservation of the structural integrity of the compounds when administered orally may require use of enteric coatings and the like.
Numerous modifications and variations of the invention are expected to occur to those skilled in the art upon consideration of the foregoing description. Only such limitations as appear in the appended claims should be placed upon the invention. | Bouvardin (C 40 H 48 N 6 O 10 ) and deoxybouvardin (C 40 H 48 -N 6 O 9 ), bicyclic hexapeptides isolated from Bouvardia ternifolia are provided in the form of pure materials, individually, and as a mixture with each other. The pure materials exhibit significant anti-neoplastic disease activity in vivo and in vitro. | 0 |
BACKGROUND OF THE INVENTION
The present invention relates to sealing devices and more particularly, to the seals of a chamber for treating a strip-like material under overpressure.
The present invention will be used to the best of advantage in the textile dyeing and finishing production, particularly in the chambers wherein the fabric is treated at elevated temperatures in steam or water media.
DESCRIPTION OF THE PRIOR ART
Known in the prior art are seals of the chambers for treating a strip-like material under overpressure (see, for example, U.S. Pat. No. 3,320,776, Cl. 68-5) which are capable of functioning only being filled with water. There are other known seals (see U.S. Pat. Nos. 3,367,151 and 3,255,616, Cl. 68-5) wherein the lubricant does not fill the entire casing but still there is a risk of the processed fabric being splashed with lubricant.
Besides, the lubricant here cannot be collected and returned into the working zone which results in excessive consumption of the lubricating material. And there are no appliances for cooling or heating the lubricant which might be necessary for some kinds of lubricant.
When solving the problem of providing a reliable seal for continuous treatment of fabric under pressure, many known technical solutions include a seal incorporating such friction pairs as stainless steel and heat-resistant synthetic rubber. It is common knowledge that such a friction pair operates within an extremely wide range of loads and velocities but calls for liberal lubrication and reliable cooling. The lubricating and cooling agent can be machine oil, oil-water emulsion or condensate of water steam, the latter being most preferable because its temperature cannot rise above the temperature of saturated steam used for treating the fabric. However, irrespective of the kind of lubricant, especially when the end and cylindrical surfaces of the rollers are liberally and efficiently lubricated, said lubricant is liable to be splashed on the fabric being processed which always leads to wastage of the latter. In addition, when lubrication is carried out with water steam condensate at temperatures approaching the temperature of processing, the protruding surfaces of the lubricant discharge appliance become covered with condensate which, due to vibrations of the processed fabric, also gets on its surface and brings about its wastage.
In the circumstances requiring liberal lubrication the use of an open-circuit lubricating system becomes extremely impracticable from the viewpoint of economy of seal operation because it involves a large consumption of lubricating fluid. The use of a recirculating system leads inevitably to the introduction of heat-exchanging devices for cooling some types of lubricant and heating the other ones.
OBJECTS OF THE INVENTION
An object of the present invention is to provide a device for lubrication of a roller seal which would permit continuous treatment of fabric under pressure and prevent the droplets of lubricant from getting on said fabric.
Another object of the invention is to provide a device for lubrication of a roller seal which would prevent accumulation of undue moisture on the surfaces of parts (baffle plates) which might get in contact with the fabric being treated.
One more object of the present invention is to provide a device for lubrication of a roller seal which would give a saving in the lubricating fluid.
And still another object of the present invention is to provide such a device which would ensure long life of the roller seal and a high quality of the treated fabric.
SUMMARY OF THE INVENTION
These and other objects are accomplished according to the present invention by providing a device for lubrication of a roller seal consisting of parallel rollers rotating in contact with one another and passing between them the treated fabric in a vertical plane, and comprising a roller lubricating appliance, a lubricant discharge appliance, a heating unit and a group of baffle plates arranged in two tiers, one upon the other in the lubricant drip-down zone; this device is characterized in that the lubricant discharge appliance is made in the form of a circular container located under the rollers between said two tiers of the baffle plates which collect the dripping lubricant into said containers while said heating unit is constituted by a tubular air heater which is in thermal contact with said circular container communicating with the pipe line of the roller lubricating appliance.
Such a technical solution permits all of the lubricant which drips downwardly to be collected without waste and the treated fabric to be protected against the splashes of the lubricating agent irrespective of the intensity of its movement. In addition, such a technical solution permits the use of a well-cooled lubricating agent and makes it possible to avoid over-moistening of the fabric delivered into the overpressure zone by heating the latter.
According to the embodiment of the present invention disclosure is made of a device for lubrication of a roller seal characterized in that said circular container of the lubricant discharge appliance is connected by a recirculating pipe incorporating a pump with the pipe line of the roller lubricating appliance.
Such a technical solution permits economical use of the lubricant which can be returned into the friction zone and gives a reduction not only in the lubricant consumption but also in the thermal energy because the temperature of lubricant must be constant and, if additional quantities of it are introduced, they have to be heated. Therefore, the greater the lubricant leaks, the higher the energy consumption.
According to another embodiment of the present invention, disclosure is made of a device for lubrication of a roller seal characterized in that if the rollers are lubricated with machine oil, said device is provided with a heating heat exchanger located at the end of the pipe line of the roller lubricating appliance in the zone after the point where said recirculating lubricant is supplied into said pipe line.
Such a technical solution permits not only maintaining the lubricant temperature at a preset level but also, if necessary, preventing accumulation of water steam condensate in the lubricating agent.
According to still another embodiment of the present invention, disclosure is made of a device for lubrication of a roller seal characterized in that, if the rollers are lubricated with condensate of water steam, said device incorporates a cooling heat exchanger installed in the recirculating pipe at the point of lubricant discharge from the circular container.
Such a technical solution ensures efficient use of lubricating agent in the form of water steam condensate which is accumulated inevitably in the vessels filled with saturated water steam under pressure. The condensate can be cooled to 10°-30° C. below the working temperature. Being cooled, the water steam condensate is an effective lubricating agent since it forms no scale when it boils out in the zone of friction. Besides, by cooling the circulation zone it becomes possible to prevent completely the boiling of condensate in the zone of friction.
DESCRIPTION OF THE DRAWINGS
Now the present invention will be described in detail by way of example with reference to the accompanying drawings, in which:
FIG. 1 is a schematic cross section of the seal in a chamber for treating a strip-like material under overpressure according to the invention;
FIG. 2 is a section taken along line II--II in FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The seal of the chamber for treating a strip-like material under overpressure comprises a hollow casing 1 (FIG. 1) mounted on a chamber 2 for treating fabric 3. The hollow casing 1 has the shape of a horizontally arranged cylinder.
The hollow casing 1 accommodates a pair of driving rollers 4 for conveying the fabric being treated, and a sealing device 5. This device 5 jointly with the rollers 4 maintains overpressure in the chamber 2 and carries the fabric 3 into, or out of, the chamber 2.
According to the invention, the seal casing 1 incorporates an upper pair of baffle plates 6 and lower pair of baffle plates 7 arranged on both sides of the fabric 3. Each pair of the baffle plates 6 and 7 has bars 8 and 9 fixed at the free ends. The baffle plates 6 are tightly connected with the side walls 10, 11 (FIG. 2) which form, together with the baffle plates 6, a circular channel constituting a container 12 filled with lubricant 13. Located between the baffle plates 6 and the fabric 3 are air heaters 14 which are heated with saturated steam supplied through a pressure regulator (not shown in the drawing). The air heaters 14 are provided with a condensate remover 15. The circular channel likewise has a condensate remover 16.
Arranged below the level of the lubricant 13 in container 12 is a recirculating pipe line 17 communicating through a cooling heat exchanger 18, pump 19, at least one filter 20, and heating heat exchanger 21 with the pipe line 22 delivering lubricant to the cylindrical surface of the rollers 4 and with the system 23 delivering lubricant to the end surfaces of the rollers 4. The lubricant supply systems 22 and 23 are provided, each, with a pressure regulating appliance, e.g. a cock 24 and a pressure gauge 25. Installed between the pump 19 and the filter 20 is a valve 26. A channel 27 with a valve 28 located between the valve 26 and the filter 20 serves for filling the system with lubricant.
The discharge seal wherein the rollers 4 rotate in the directions shown by arrows in FIG. 1 must be provided with scrapers 29 and plate springs 30 for removing the surplus lubricant which remains on the surface of rollers 4. The scrapers 29 are articulated on pins 31 secured in the seal casing 1. All the springs are fastened to each respective scraper 29 at one end and to an elongate holder 32 at the other, said holder resting on a respective one of the bars 8. The filter 20 must be made up of one or more filtering portions cut in parallel into the pipe line thus permitting one of the sections to be disconnected and cleaned without the drop of pressure in the line. The necessity for cleaning will become apparent by measuring the pressure drop on the filter with the aid of a differential pressure gauge or two ordinary pressure gauges (not shown in the drawings) which measure pressure before and after the filter. The reference pressure gauge should be of an electric contact type sending an emergency signal or a command pulse for stopping the rollers.
The device functions as follows. Any type of lubricant suitable for lubricating the friction pair, i.e., the friction rollers 4, is supplied through the open valve 28 until it starts flowing out of the condensate remover 16. The air heater 14 is heated with steam at such a pressure such that no drops of lubricant fall on the fabric. The steam condensate is removed through the condensate remover 15. Prior to turning on the drive of the rollers 4, the pump 19 is started and the supply of lubricant into the friction zones is adjusted by means of the cocks 24, the pressure in the corresponding channels being checked by the pressure gauges 25. To ensure reliable lubrication, the lubricant is always supplied into the zones of friction in surplus quantities. The surplus lubricant 13 from the friction zone drips down along the walls of the casing 1 while in the discharge seal it flows down along the casing walls and the scrapers 29. These scrapers 29 remove uniformly the surplus lubricant from the surface of the corresponding rollers 4 because each of them is uniformly pressed against the surface of the roller 4 by plate springs 30 as shown in FIGS. 1 and 2. In case of radial shifting of the rollers said springs 30 turn the scrapers 29 on the pins 31, ensuring reliable and constant contact between the cylindrical surfaces of the rollers 4 and scrapers 29. Thus, the fabric 3 is reliably protected against the splashes of lubricant by the scrapers 29 and baffle plates 6. The bars 8 and 9 keep the fabric out of contact with the heated air heater 14.
If the rollers are lubricated with a material which is not to be mixed with the water steam condensate, the fluid is heated by the heating heat exchanger 21. If, however, they are lubricated with water steam condensate or with water emulsions, the lubricating fluid must be cooled by the cooling heat exchanger 21 in which case the heating heat exchanger 18 is inoperative. When the device is lubricated with a material at a temperature which is lower than the fabric processing temperature, the external surfaces of the baffle plates become covered with accumulated condensate. This condensate is prevented from getting on the fabric by the baffle plates 7. The pure condensate accumulated after the baffle plates 7 is removed by any known method together with the condensate formed on the walls of the chamber 2. | The device comprises a circular container for collecting the dripping down lubricant. Said container is located between the tiers of baffle plates and is connected by a recirculating pipe line with the roller lubricating pipe line. The device incorporates a tubular air heater which heats the surfaces of the baffle plates that might get in contact with the fabric being processed, and a heat exchanger in the lubricant supply line. | 3 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a vacuum circuit breaker which is excellent in high current breaking characteristics, and more particularly, it relates to contact material for the same.
2. Description of the Prior Art
Vacuum circuit breakers, which are maintenance-free, pollution-free and excellent in breaking performance, have been widely used in the art. With development thereof, awaited is provision of circuit breakers applicable to both higher voltage and higher current.
Performance of a vacuum circuit breaker mainly depends on contact material for the same. Such contact material is preferable to have (1) larger breaking capacity, (2) higher withstand voltage, (3) lower contact resistance, (4) smaller force required to separate welded contacts, (5) smaller contact consumption, (6) smaller chopping current, (7) better machinability and (8) sufficient mechanical strength.
It is practically difficult to obtain a contact material having all of the said preferable characteristics. In practical contact material, therefore, only particularly important characteristics required for a specific use are improved at the sacrifice of the other characteristics. For example, a copper (Cu) - tungsten (W) contact material as disclosed in Japanese Patent Laying-Open Gazette No. 78429/1980 is excellent in withstand voltage performance, and thus commonly applied to load switchs, contactors etc. However, the Cu-W contact material is not so much satisfactory in current breaking performance.
On the other hand, a copper (Cu) - chromium (Cr) contact material disclosed in, e.g., Japanese Patent Laying-Open Gazette No. 71375/1979 is remarkably excellent in breaking performance, and thus commonly applied to circuit breakers etc. However, the Cu-Cr contact material is inferior in withstand voltage performance to the Cu-W contact material.
In addition to the aforementioned examples, examples of contact materials generally used in the air or oil are described in literature such as "General Lecture of Powder Metallurgy" edited by Yoshiharu Matsuyama et al. and published (1972) by Nikkan Kogyo Shinbun. However, such contact materials of silver (Ag) - molybdenum (Mo) and Cu-Mo systems as described in "General Lecture of Powder Metallurgy" pp. 229-230 are inferior in withstand voltage performance to the aforementioned Cu-W contact material as well as in current breaking performance to the said Cu-Cr contact material, and thus are scarcely applied to vacuum circuit breakers at present.
As mentioned above, practically selected and employed is a contact material which is excellent in characteristics required for a specific use. However, desired in recent years are vacuum circuit breakers which are applicable to both higher current and higher voltage, and it is difficult to satisfy characteristics required therefor by a conventional contact material. Further, a contact material having higher performance is desired also for miniaturizing the vacuum circuit breakers.
SUMMARY OF THE INVENTION
Accordingly, an object of the present invention is to provide contact materials for the vacuum circuit breaker which are excellent in breaking performance with improvement in characteristics.
The contact material for the vacuum circuit breaker according to the present invention comprises (1) copper, (2) molybdenum and (3) niobium (Nb) or tantalum (Ta).
The above and other objects, features, aspects and advantages of the present invention will become more apparent from the following detailed description of the present invention when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1A and 1B are graphs respectively showing normalized breaking performance of Cu-Mo-Nb and Cu-Mo-Ta contact materials prepared by an infiltration method in accordance with the present invention;
FIGS. 2A and 2B are graphs respectively showing normalized breaking performance of Cu-Mo-Nb and Cu-Mo-Ta contact materials prepared by a powder sintering method in accordance with the present invention; and
FIGS. 3A and 3B are graphs showing normalized breaking performance of Cu-Mo-Nb and Cu-Mo-Ta contact materials prepared by a hot press method in accordance with the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Preparation of Contact Material
Three sample groups of contact materials were prepared by three methods of applied powder metallurgy, i.e., an infiltration method, a powder sintering method and a hot press method.
In the infiltration method, for example, Mo powder of 3 μm in mean grain size, Nb powder of grain size less than 40 μm and Cu powder of grain size less than 40 μm have been mixed in the ratio of 75.7:7.8:16.5 at weight percentage (wt. %) for two hours. The mixed powder was then filled in dies of prescribed geometry, to be compacted by a press under a pressure of 1 ton/cm 2 . The compact thus formed has been sintered at 1000° C. for two hours in a vacuum, thereby to obtain loosely sintered compact. A block of oxygen-free copper was placed on the loosely sintered compact, which were then kept at 1250° C. for one hour in a hydrogen atmosphere, to obtain a contact material impregnated with oxygen-free copper. The final composition of this contact material is that of a sample 2N as shown in Table 1A. Table 1A lists up the samples of the Cu-Mo-Nb system prepared by the infiltration method, in which a sample 1R containing no Nb was prepared for reference.
Similarly, Table 1B shows samples of the Cu-Mo-Ta system prepared by the infiltration method under the same processing conditions as above.
TABLE 1A______________________________________(Infiltration Method)Sample Composition (wt. %) IACS (%)*______________________________________ 1R Cu--50.2Mo 60.5 2N Cu--31.3Mo--3.7Nb 70.3 3N Cu--28.4Mo--11.6Nb 71.3 4N Cu--48.6Mo--2.4Nb 65.5 5N Cu--45.3Mo--4.7Nb 62.8 6N Cu--40.5Mo--9.5Nb 64.0 7N Cu--35.7Mo--14.3Nb 61.3 8N Cu--25.7Mo--24.3Nb 62.2 9N Cu--15.5Mo--34.5Nb 63.710N Cu--57.2Mo--2.8Nb 58.211N Cu--54.4Mo--5.6Nb 55.312N Cu--48.7Mo--11.3Nb 53.613N Cu--42.9Mo--17.1Nb 44.114N Cu--30.8Mo--29.2Nb 50.415N Cu--18.6Mo--41.4Nb 49.8______________________________________ *IACS: International Annealed Copper Standard
TABLE 1B______________________________________(Infiltration Method)Sample Composition (wt. %) IACS (%)______________________________________ 1R Cu--50.2Mo 60.5 2T Cu--33.2Mo--6.8Ta 59.7 3T Cu--22.4Mo--17.6Ta 55.5 4T Cu--45.6Mo--4.4Ta 62.4 5T Cu--41.5Mo--8.5Ta 58.0 6T Cu--34.2Mo--15.8Ta 53.5 7T Cu--27.9Mo--22.1Ta 50.2 8T Cu--17.5Mo--32.5Ta 45.4 9T Cu--5.0Mo--45.0Ta 48.910T Cu--54.7Mo--5.3Ta 54.411T Cu--49.8Mo--10.2Ta 48.412T Cu--41.1Mo--18.9Ta 44.413T Cu--33.5Mo--26.5Ta 47.214T Cu--21.0Mo--39.0Ta 46.415T Cu--6.0Mo--54.0Ta 44.3______________________________________
In the powder sintering method, for example, Mo powder of 3 μm in mean grain size, Nb powder of grain size less than 40 μm and Cu powder of grain size less than 75μm have been mixed in the ratio of 38.1:1.9:60 at weight percentage for two hours. The mixed powder was then filled in dies of prescribed geometry, to be compacted by a press under a pressure of 3.3 ton/cm 2 . The compact thus formed has been sintered in a hydrogen atmosphere at a temperature just below the melting point of copper for two hours, thereby to obtain a contact material. This contact material is shown as a sample 17N in Table 2A, which lists up the samples of the Cu-Mo-Nb system obtained by the powder sintering method. A sample 16R containing no Nb and a sample 23R of the Cu-Cr system are shown for reference.
Similarly, Table 2B shows samples of the Cu-Mo-Ta system prepared by the powder sintering method. These samples were prepared under the same conditions as those for the Cu-Mo-Nb system contact material.
TABLE 2A______________________________________(Powder Sintering Method)Sample Composition (wt. %) IACS (%)______________________________________16R Cu--25Mo 66.917N Cu--38.1Mo--1.9Nb 55.518N Cu--36.2Mo--3.8Nb 55.019N Cu--28.6Mo--11.4Nb 61.320N Cu--23.8Mo--1.2Nb 74.921N Cu--22.6Mo--2.4Nb 73.622N Cu--17.9Mo--7.1Nb 60.623R Cu--25Cr 41.8______________________________________
TABLE 2B______________________________________(Powder Sintering Method)Sample Composition (Wt. %) IACS (%)______________________________________16R Cu--25Mo 66.917T Cu--36.5Mo--3.5Ta 57.018T Cu--33.2Mo--6.8Ta 56.419T Cu--22.4Mo--17.6Ta 52.020T Cu--22.8Mo--2.2Ta 73.721T Cu--20.7Mo--4.3Ta 71.222T Cu--14.0Mo--11.0Ta 62.223R Cu--25Cr 41.8______________________________________
In the hot press method, for example, Mo powder of 3 μm in mean grain size, Nb powder of grain size less than 40 μm and Cu powder of grain size less than 75 μm have been mixed in the ratio of 38.1:1.9:60 at weight percentage for two hours. The mixed powder was then filled in carbon dies to be heated at 1000° C. under a pressure of 200 Kg/cm 2 in a vacuum, thereby to obtain a contact material ingot. The contact material thus obtained is shown as a sample 25N in Table 3A, which lists up the samples of the Cu-Mo-Nb system prepared by the hot press method. A sample 24R containing no Nb was prepared for reference.
Similarly, Table 3B shows samples of the Cu-Mo-Ta system prepared by the hot press method. Conditions for preparing the same were identical to those for the samples of the Cu-Mo-Nb system.
TABLE 3A______________________________________(Hot Press Method)Sample Composition (wt. %) IACS (%)______________________________________24R Cu--25Mo 76.125N Cu--38.1Mo--1.9Nb 62.526N Cu--36.2Mo--3.8Nb 62.027N Cu--28.6Mo--11.4Nb 68.328N Cu--23.8Mo--1.2Nb 75.829N Cu--22.6Mo--2.4Nb 75.530N Cu--17.9Mo--7.1Nb 72.8______________________________________
TABLE 3B______________________________________(Hot Press Method)Sample Composition (wt. %) IACS (%)______________________________________24R Cu--25Mo 76.125T Cu--36.5Mo--3.5Ta 72.026T Cu--33.2Mo--6.8Ta 61.327T Cu--22.4Mo--17.6Ta 54.028T Cu--22.8Mo--2.2Ta 75.329T Cu--20.7Mo--4.3Ta 73.830T Cu--14.0Mo--11.0Ta 71.0______________________________________
Characteristics of Contact Material
The respective samples of the contact materials prepared by the said methods were machined into electrodes of 20 mm in diameter, and then subjected to measurement of electric conductivity. The results are included in Tables 1A, 1B, 2A, 2B, 3A and 3B, and it is obvious that most of the samples are equivalent to or higher than the reference sample 23R of the conventional Cu-Cr contact material in electric conductivity.
The said electrodes were assembled into standard circuit breakers, to be subjected to measurement of electric characteristics. FIG. 1A shows normalized breaking performance of the samples prepared by the infiltration method as shown in Table 1A. The contact materials according to the present invention are of the ternary system, and hence the abscissa indicates the content of Nb with respect to Mo, i.e., the total weight percentage of Mo and Nb is 100%. The ordinate indicates the normalized breaking performance with reference to the conventional Cu - 50 wt. % Mo contact material, i.e., the value of the current breakable through the standard vacuum circuit breaker, with reference to the Cu - 50 wt. % Mo contact material as shown by a double circle 4 in FIG. 1A.
A curve 1 in FIG. 1A represents breaking performance of the Cu-Mo-Nb samples 2N and 3N respectively containing about 60 wt. % Cu as shown in Table 1A. A curve 2 represents breaking performance of the Cu-Mo-Nb samples 4N, 5N, 6N, 7N, 8N and 9N respectively containing about 50 wt. % Cu and the Cu - 50.2 wt. % Mo sample 1R containing no Nb as shown in Table 1A. A curve 3 in FIG. 1A represents breaking performance of the Cu-Mo-Nb samples 10N, 11N, 12N, 13N, 14N and 15N respectively containing about 40 wt. % Cu as shown in Table 1A. A line 5 in FIG. 1A represents breaking performance of the sample 23R of the conventional Cu - 25 wt. % Cr contact material prepared by the powder sintering method for reference.
Similarly, FIG. 1B shows breaking performance of the Cu-Mo-Ta contact material prepared by the infiltration method as shown in Table 1B.
As an example of the breaking performance, a current of 12.5 KA at 7.2 KV was satisfactorily broken by the sample 5N or 4T of 20 mm in diameter assembled into the standard vacuum circuit breaker.
It is understood from FIGS. 1A and 1B that the contact materials of the Cu-Mo-Nb and Cu-Mo-Ta systems prepared by the infiltration method is superior in breaking performance to the conventional Cu-Cr contact material. In the infiltration method, the samples were prepared within the range of 2.4-41.4 wt. % Nb and 15.5-57.2 wt. % Mo, or 4.4-54.0 wt. % Ta and 5.0-54.7 wt. % Mo. With respect to the contact materials being superior in breaking performance to the conventional Cu-Cr contact material, it is believed that contents of Mo and Nb, or Mo and Ta may be in wider ranges. However, increase in the contents of Ta, Nb and Mo generally involves increased cost and deteriorated machinability. Therefore, optimum compositions can be selected in consideration of electric characteristics as well as cost and mechanical characteristics.
FIG. 2A shows normalized breaking performance of the Cu-Mo-Nb samples prepared by the powder sintering method as listed in Table 2A. In FIG. 2A, the abscissa indicates the Nb content with respect to Mo similarly to FIG. 1A, while the ordinate indicates the breaking performance with reference to a contact material of Cu - 25 wt. % Mo (sample 16R) as shown by a double circle 8. A curve 6 represents breaking performance of samples 20N, 21N, 22N and 23N of the Cu-Mo-Nb contact material respectively containing about 75 wt. % Cu and the reference sample 16R as shown in Table 2A. A curve 7 in FIG. 2A represents breaking performance of the samples 17N, 18N and 19N of the Cu-Mo-Nb system respectively containing about 60 wt. % as shown in Table 2A. A line 5 in FIG. 2A represents breaking performance of conventional Cu - 25 wt. % Cr contact material for reference, similarly to FIG. 1A.
In a similar manner, FIG. 2B shows breaking performance of the Cu-Mo-Ta contact material prepared by the powder sintering method as shown in Table 2B.
It is understood from FIGS. 2A and 2B that the contact materials of the Cu-Mo-Nb and Cu-Mo-Ta systems prepared by the powder sintering method are also superior in breaking performance to the conventional Cu-Cr contact material. While compositions of the contact materials prepared by the powder sintering method were within the ranges of 1.2-11.4 wt. % Nb and 1.79-38.1 wt. % Mo, or 2.2-11.0 wt. % Ta and 1.40-36.5 wt. % Mo, the contact materials in wider ranges of these contents are believed to be superior in breaking performance to the conventional Cu-Cr contact material.
FIG. 3A shows breaking performance of the contact material prepared by the hot press method as shown in Table 3A. Similarly to FIG. 1A, the abscissa indicates the Nb content with respect to Mo. The ordinate indicates the breaking performance with reference to a contact material of Cu - 25 wt. % Mo (sample 24R) prepared by the hot press method, with the reference being shown by a double circle 11. A curve 9 in FIG. 3A represents the breaking performance of the Cu-Mo-Nb samples 28N, 29N and 30N respectively containing about 75 wt. % Cu and the reference sample 24R as shown in Table 3A. A curve 10 represents the breaking performance of samples 25N, 26N and 27N respectively containing about 60 wt. % Cu as shown in Table 3A. Similarly to FIG. 1A, a line 5 represents the breaking performance of the conventional contact material of Cu - 25 wt. % Cr (sample 23R) for reference.
In a similar manner, FIG. 3B shows breaking performance of the Cu-Mo-Ta contact material prepared by the hot press method as shown in Table 3B.
It is understood from FIGS. 3A and 3B that the contact materials of the Cu-Mo-Nb and Cu-Mo-Ta systems prepared by the hot press method are also superior in breaking performance to the conventional Cu-Cr contact material. Similarly to Tables 2A and 2B, compositions of the contact material prepared by the hot press method were within the ranges of 1.2-11.4 wt. % Nb and 17.9-38.1 wt. % Mo, or 2.2-11.0 wt. % Ta and 14.0-36.5 wt. % Mo, but the contact materials of these systems in wider ranges of the contents are believed to be superior in breaking performance to the conventional Cu-Cr contact material.
Referring to the curves 1, 7 and 10 in FIGS. 1A, 2A and 3A, comparison can be made on the Cu-Mo-Nb samples containing about 60 wt. % Cu prepared by different methods, whereas no remarkable difference is observed except for that the samples prepared by the hot press method are somewhat better in breaking performance than the other samples. While the samples of the Cu-Mo-Nb contact material were investigated within the ranges of 15.5-57.2 wt. % Mo and 1.2-41.4 wt. % Nb, the breaking performance thereof is believed to be excellent in a wider range of the Nb content, since the performance is increased with increase of the Nb content in each of FIGS. 1A, 2A and 3A. Although the Cu-Mo-Nb samples containing 40 wt. % Cu are lower in breaking performance in certain ranges of the Mo and Nb contents than the other Cu-Mo-Nb samples in FIG. 1A, the same are sufficiently applicable in practice since the breaking performance is increased with increase of the Nb content.
Similarly, comparison can be made on the Cu-Mo-Ta samples containing about 60 wt. % Cu prepared by different methods, with reference to the curves 1, 7 and 10 as shown in FIGS. 1B, 2B and 3B. However, only slight difference in breaking performance is observed between the samples. Although the Cu-Mo-Ta samples were investigated within the range of 5.0-54.7 wt. % Mo and 2.2-54.0 wt. % Ta, the contact material containing a higher content of Ta is believed to be excellent in breaking performance since the breaking performance is increased with increase of Ta content in each of FIGS. 1B, 2B and 3B.
Although the present invention has been described and illustrated in detail, it is clearly understood that the same is by way of illustration and example only and is not to be taken by way of limitation, the spirit and scope of the present invention being limited only by the terms of the appended claims. | Contact material for vacuum circuit breaker according to the present invention contains (1) copper, (2) molybdenum, and (3) niobium or tantalum. | 7 |
FIELD OF THE INVENTION
[0001] The invention relates to an anchoring device to which personnel safety lines may be attached. The anchoring device is particularly adapted for use with the fixed castings or receptacles commonly found on cargo containers and the decks of ships. More specifically, the anchoring device is releasably secured within the casting.
DESCRIPTION OF THE RELATED ART
[0002] The shipping and transportation of cargo in containerized units is a common world wide practice, the containers being loaded and unloaded onto ships, trucks, railway cars and the like.
[0003] Typically, each container is provided at each corner with top and/or side casting or female receptacles to enable the container to be lifted using a lifting beam or spreader having twist locks or a mechanical equivalent at each of the four corners. The twist locks have male connections which are lowered or inserted sideways into engagement with the comer castings. An exemplary twist lock is described in U.S. Pat. No. 3,749,438 to Loomis et al. This patent also provides useful background information on the art of handling cargo containers in general. Furthermore, such castings are also usually provided on the decks of container ships in order to facilitate container handling.
[0004] The heights of stacked containers, either in the ship's hold or decks or on dry land, are dangerous for personnel moving on stacked containers or working on decks. In bad weather there exists a need to provide a personnel safety anchor to which a life line may be secured. This anchor, preferably, would be secured to the container or deck mechanically and provide means for securing a shock-absorbing lanyard or retractable safety line releasably thereto. In turn such a safety line would be attached to a full body harness worn by the individual. A search of the prior art failed to locate a releasably secured anchoring device whereby the personnel could, when harnessed to a lifeline, be free to safely move about on containers, decks or the like.
SUMMARY OF THE INVENTION
[0005] It is a primary objective of the present invention to provide an anchoring device which is adapted for insertion and removal into and from the top and side openings of corner castings on the roof or sides of a container or on a ship's deck. The anchoring device is designed to be used in conjunction with a shock-absorbing lanyard or self-retracting lifeline which is attached to a personal safety harness fitted on the individual.
[0006] Broadly stated the invention comprises an anchoring device adapted to be utilized in combination with means for securing personnel to said anchoring device, said anchoring device further being adapted to be releasably secured within a receptacle sized to receive said anchoring device which comprises: a housing sized to be received within said receptacle; means for releasably securing said housing within said receptacle; and means associated with said housing for connecting said personnel securing means thereto.
[0007] Advantageously, as a result of this invention there is provided a portable anchoring device which is functional to automatically lock into the steel corner castings of shipping containers or the castings formed on the decks of container ships. Furthermore, the anchoring device is easily released from the locked position within the casting by simple depression of an actuator provided thereon.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The anchoring device of invention will now be described with reference to the accompanying drawings, in which:
[0009] [0009]FIG. 1 is a perspective view of the anchoring device of the present invention;
[0010] [0010]FIG. 2 is a side elevation view of the anchoring device of FIG. 1;
[0011] [0011]FIG. 3 is a sectional view of the housing and handle socket of the anchoring device, partly in elevation, taken through line 3 - 3 of FIG. 1;
[0012] [0012]FIG. 4 is an end elevation of the housing and pivot pin of the anchoring device of FIG. 1;
[0013] [0013]FIG. 5 is a plan view depicting the angle of travel of the handle assembly of the anchoring device of FIG. 1; and
[0014] [0014]FIG. 6 is a perspective view of the anchoring device of FIG. 1 depicting the device in its operating position secured in a container casting in combination with the shock-absorbing lanyard secured to a personal full body harness.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0015] The invention can be anchored to the top or side openings of a container or ship. For purposes of clarity, the description focuses on the upright orientation of the invention. Having reference to the accompanying drawings, the anchoring device 10 of the present invention comprises a housing 12 provided with a pair of locking jaws 14 functional to releasably secure the anchoring device 10 within the cavity 11 of castings 16 set in the top corners or side walls of a cargo-carrying container 18 , or ship's deck, or the like. Mounted on the top of the housing 12 is an anchor plate 20 to which may be releasably attached the lanyard or lifeline 80 . Above the anchor plate 20 extends a pivot pin 22 to which is operatively connected a handle socket 24 adapted to receive an elongated shaft 26 , said shaft 26 being provided at its upper and distal end with a handle assembly generally designated 28 which is functional to actuate the locking jaws.
[0016] Having particular reference to FIG. 3, the housing 12 comprises a generally U-shaped lower section 30 and an upper horizontal plate 32 defining a generally central circular aperture 31 therein. Plate 32 is sized to sit upon a portion of the upper wall or the side of the container 18 (FIG. 6) surrounding the casting 16 . A pair of V-shaped ribs 38 are mounted on the opposite outer walls 30 a of the U-shaped lower section 30 of the housing 12 for guiding housing 12 into the cavity in casting 16 . A pair of opposed locking jaws 14 are pivotally mounted within the housing 12 at their proximal ends by means of pivot pins 40 secured by rivets or nuts and bolts, not shown. The locking jaws 14 are retractable, their distal ends normally extending upwardly and outwardly from the open ends of U-shaped lower section 30 , as viewed in FIG. 3. Locking jaws 14 are generally rectangular in shape defining at their upper outer distal ends a square cut away portion 14 a . A compression jack spring 42 extends between the lower sections 14 b of the locking jaws 14 being secured thereto by insertion into opposed cavities 43 , 43 a . To each of connector pins 44 a , 44 b mounted on locking jaws 14 are secured the ends 46 a and 46 b respectively of a doubled-up release cable 46 . The release cable ends 46 a and 46 b are guided in opposite directions over a diverter rod 48 secured by means of a cotter pin 50 (FIG. 4). The cable ends 46 a and 46 b are suitably tensioned by means of compression spring 42 and the doubled-up cable 46 fed through a bore 56 defined in the pivot pin 22 which extends through aperture 31 of the housing top plate 32 . The cable ends 46 a and 46 b are crimped to convertor pins 44 a , 44 b respectively as shown in FIG. 3 forming the unitary release cable 46 , the operation of which being described hereinafter.
[0017] As stated earlier, the vertical pivot pin 22 defines an internal bore 56 , forming at its lower end a circumferential flange 58 abutting the underside of plate 32 . Above the housing top plate 32 is mounted the oval anchor plate 20 which defines an upwardly extending lip 20 a having a generally central circular aperture 36 defined therein. The aperture 36 is adapted to receive a carabiner 78 or the like to which may be attached the retractable shock-absorbing lanyard 80 or safety line (FIG. 6).
[0018] A pair of opposed rectangular plates 60 (FIG. 2) are provided on each side of the vertical pivot pin 22 being secured one to another by means of a nut and bolt assembly 62 . The handle socket 24 , sized to fit into plates 60 at an angle thereto, comprises a pair of opposed plates 61 having a sleeve 64 secured there between by means of nut and bolt assemblies 66 . The release cable 46 extending vertically through the bore of pivot pin 22 is guided over a cable guide roller 68 upwardly through sleeve 64 and into the shaft 26 connected thereto. The shaft 26 extends angularly upwardly to the handle and locking jaw actuator assembly 28 .
[0019] As illustrated in FIG. 5, pivot pin 22 is functional to permit rotation of the handle socket 24 , shaft 26 and handle assembly 28 through an angle α of about 45 degrees on each side of the centre of the horizontal axis 29 of the casting 16 .
[0020] The handle and locking jaw actuator assembly 28 (FIGS. 1 and 2) are made up as follows. To the shaft 26 is secured an industrial grip 29 , the grip 29 having a trigger 67 which is pivotally mounted on the grip 29 in a pair of opposed tabs 31 formed on grip 29 and secured by means of rivets or a nut and bolt assembly 76 . Trigger 67 is functional upon depression thereof for retraction of cable 46 to retract the locking jaws 14 inwardly towards each other, thus enabling the anchoring device 10 to be detached from the casting 16 . More specifically, the doubled-up release cable 46 is attached to the lower end of nylon piston 70 extending internally through the grip 29 . The piston 70 passes through an extension 74 formed at the distal end of the hand actuated trigger 67 . The top of the piston 70 receives locking nut 72 which engages trigger extension 74 to enable lifting and extension of the release cable 46 .
[0021] In operation, the anchoring device 10 is guided downwardly or sideways into a cavity 11 receptacle of a casting 16 whereby the projecting ends of spring-loaded jaws 14 are depressed towards each other into housing 12 for outwardly snap-engagement with the underside of lip 100 of casting 16 (FIG. 3), thereby locking anchoring device 10 into casting 16 . The user is attached to housing 12 by a lanyard 80 secured thereto by carabiner 78 . The user can quickly detach the anchoring device 10 from castings 16 by squeezing the trigger 67 as the distal ends of shaft 26 to extend cable 46 outwardly from handle assembly 28 , thereby retracting normally outwardly-biased jaws 14 inwardly for release from casting lips 100 . Handle 28 or shaft 26 can be pivoted through 90° of arc for convenience of access to the user.
[0022] The anchoring device of the invention provides a safety anchor for personnel moving and working on stacked containers or on heaving ship decks. The anchoring device can be quickly guided and easily snapped into engagement with the castings and receptacles present on containers and ship decks and readily detached from the castings when desired by the user.
[0023] It will be understood, of course, that modifications can be made in the embodiments of the invention described herein without departing from the scope and purview of the invention as defined by the appended claims. | An anchoring device for use in combination with personnel securing assemblies. The anchoring device is adapted for engagement within a receptacle sized to releasably receive said device. The anchoring device comprises a housing receivable within said receptacle, a pair of opposed locking jaws mounted within said housing and anchoring means secured to said housing. Pivotally connected to said housing are means for releasably extending and retracting said locking jaws into engagement with said receptacle. The locking jaws are operative to engage the receptacle in releasable locking engagement therewith. The anchoring means are functional to have personnel securing assemblies releasably connected thereto. | 0 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a method for entering, archiving, consulting and transmitting a document to an addressee by means of a camera optionally integrated to a communications terminal, of a server and a terminal.
[0003] The method according to the invention is particularly adapted to a communications terminal fitted with a camera, but is also suitable for a camera having storage means which may be connected to a communications terminal.
[0004] This method is notably but not exclusively applied to capturing an image of a paper document or a document present on any other support or media (black or white board, paperboard, panel, and screen) by means of a camera optionally integrated into a communications terminal, to transmitting the image to a server, and then extracting, correcting, interpreting and archiving data contained in the image by the server, and finally to searching and consulting data archived on the server, and to transmitting them to an addressee or sharing them on a local or non-local communications network.
[0005] 2. Description of the Prior Art
[0006] When it is desired to digitize a document in order to archive or transmit it to an addressee by fax or email, a piece of equipment dedicated to digitization of documents such as a scanner, a copy machine, or a fax machine must generally be used. Further, generally, one should simultaneously have a terminal connected to the acquisition device so as to be able to store the scan and optionally transmit it by email. This requires having both of these pieces of equipment available upon digitization, which is generally not the case when one is traveling away from the office. Further, if one only has a piece of equipment with which documents may be digitized, one is often limited by its memory, and there is a risk of loosing documents when the latter saturates or is faulty. When one uses a copy machine made available outside the office, the device might not well operate for lack of ink or paper, and photocopies are not simultaneously made available to other interested and remotely located persons.
[0007] Moreover, a wire or wireless connection with a network is required for transmitting the document to an addressee by fax, email, or Internet. Thus, when a document is transmitted to an addressee from a fax machine made available during traveling, the piece of equipment is tied up for an unspecified time and this until the fax machine prints the acknowledgement of receipt.
[0008] Moreover, it is common to try and utilize document images captured by means of a camera having fixed or removable storage means, and then transmitted to a terminal by connecting the latter to the aforesaid fixed or removable storage means of the camera. If the terminal integrates a software package for touching up images, one may then try to improve legibility of textual and graphical information relating to the document, by improving the balance of whites, adjusting the luminosity, enhancing the contours, intensifying the contrast, by improving saturation, attenuating noise, reframing the view of the document, turning over or inverting the image, correcting the perspective, chromatic aberration, optical distortion, blurring, or vignetting. These tedious operations for touching up images require sustained attention and significant know-how in the field of graphics, but they do not guarantee that a result is obtained close to that of a digitization of the document by means of a scanner. Additionally, one may try to interpret the information contained in the image with a character or graphic recognition software in order to re-utilize them, which facilitates search for information and reduces the size of the digitized information.
[0009] Finally, when it is desired to transmit a document in order to share it or to publish it on a local network such as an intranet, or on a non-local network such as an Internet site, a web log, or a site for sharing files or images, and when one does not have a scanner, one may take a picture of the document by means of a camera and transmit it over the network for sharing or publication by means of a communications terminal. However, the thereby shared or published textual and/or graphical information is often not very legible notably because of defects in the image of the document, related to the lack of contrast or to poor adjustment of the balance of whites.
OBJECT OF THE INVENTION
[0010] The object of the present invention is notably to find a remedy to these drawbacks and to allow a document to be reconstructed by means of an image of the latter, and then its archiving, its consulting and its transmitting to an addressee.
SUMMARY OF THE INVENTION
[0011] In this case the method according to the invention may involve:
A communications terminal TC; A camera C with fixed or removable storage means which may be connected to the communications terminal or the camera being preferably connected and integrated to the communications terminal; A server S fitted out with a central unit assembling together processing, storage and transmission means; A terminal T fitted out with a central unit assembling processing, storage and transmission means, a keyboard and a display device; An addressee DES having receiving means, such as a terminal, with means for receiving email, a fax, a server or a terminal, connected to a local network, such as an intranet or a non-local network such as Internet.
[0017] Thus, the method according to the invention comprises the following steps:
Capturing and storing an image of the document by means of the camera C; If the camera is not connected to the communications terminal, connecting the fixed or removable memory of the camera to the communications terminal, and transferring the image into the memory of the communications terminal; Transmitting the image of the document by the communications terminal TC to the server S, as well as optionally its addressee DES and/or its title and/or a comment; Extracting, correcting, and optionally interpreting information relative to the document, contained in the image, by processing means integrated to the server S, and reconstructing it by means of the extracted, corrected, and optionally interpreted information; Archiving the document on the server S, while taking into account the information contained in the reconstructed document as well as that concerning its history; Optionally searching and/or consulting and/or modifying and/or suppressing information relative to an archived document on the server S from the terminal T, and/or from the communications terminal TC, and/or controlling its transmission to an addressee; Optionally transmitting information relative to the reconstructed document or to its history, by the server S to the addressee DES and/or to the communications terminal TC, and/or to the terminal T.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0025] Advantageously, in the event of the server S having received the image of the document transmitted by the communications terminal TC, the server S will be able to transmit an acknowledgment of receipt message to the communications terminal TC.
[0026] Advantageously, the extraction and correction of textual and/or graphical information of the image of the document may be carried out by methods for extracting raw data from an image resulting from a shot, as already proposed by the applicant in application PCT/FR05/00678 which is incorporated by reference, and comprising the following steps:
determining for each point located by column C and line L of the image, a value V 0 [C, L] consisting in a combination of components of the color of the image, calculating for each point of the image, a background value V Fond [C, L], calculating for each point of the image, the difference D [C, L], D [C, L]=V Fond−V 0 [C, L] (dark data/bright background), or V 0 [C, L]−V Fond (bright data/dark background), calculating a threshold value V S consisting in a noise contextual datum used for correcting extracted raw data D [C, L], from at least one contrast histogram and/or from the probability q that a regional maximum of raw data contains noise, correcting raw data D [C, L] by means of the noise contextual datum V S resulting in the extracted data D* [C, L], calculating for each point of the image, a corrected value I* [C, L] taking into account the corrected raw datum D* [C, L], optionally presenting the extracted data or the image containing them under a desired angle.
[0037] The same method is characterized in that, in the case of presentation of data extracted from an image or from an image containing them according to a desired angle of view, from a picture taken with a camera under any incidence, it comprises:
searching for at least four identifiable characteristic points of a pattern present in the picture taken by the camera defining contextual data, these characteristic points may consist in the corners of the image, optionally extracting data according to predetermined criteria, calculating geometrical distortions to be made to the raw image or to the extracted data or to the image containing them, from the relative position of the four points, with respect to relative positions of references, determining the corrections to be made to the raw image or to the extracted data or to the image containing them, according to the geometrical distortions, generating a corrected image taking into account the thereby determined corrections.
[0043] The same method is also characterized in that in order to obtain a corrected image with the same proportions as the object, it comprises the determination of the actual height/width ratio of the quadrilateral defined by the aforesaid points and taking this ratio r into account in the generation of the corrected image.
[0044] Thus, correction of extracted textual and/or graphical information may concern the geometry, the color, the blurring and/or the contrast, and in a non-limiting way, enhancement of the balance of whites, adjustment of the luminosity and of the contrast, enhancement of the contours, intensification of the contrast, improvement of the saturation, attenuation of the noise, reframing of the view of the document, turning over or inverting the image, correcting perspective, chromatic aberration, optical distortion, blurring or vignetting.
[0045] Advantageously, archiving of the document by the server will comprise the following steps:
generating a reduced image of the reconstructed document; generating index tables while taking into account the information relative to the document to be archived.
[0048] Advantageously, the information relative to a document contained in the reconstructed document as well as that concerning its history, may concern:
the file name of the image of the document; the optional title and/or comment transmitted by the communications terminal or terminal T; the location and/or the date and/or the time of the capture of the image of the document; the date of transmission of the image of the document to the server; the reconstruction status of the document; the reconstruction date of the document; the addressees, the dates, and the statuses of the transmissions of the document to these addressees; textual information optionally interpreted by means of a character recognition software package; graphic information possibly interpreted by a pattern recognition software package.
[0058] Advantageously, the result from the optional document information search from the terminal T or from the communications terminal TC may comprise the list of documents, for which the relative pieces of information are the ones searched for, optionally accompanied by some pieces of their relative information.
[0059] Advantageously, in the event that the quality of the resolution of the image of the document does not allow the extraction of textual or graphical information legible or interpretable by a character or pattern recognition software package, even after correction, the server S will be able to transmit a warning message to the terminal T and to the communications terminal TC, optionally accompanied by pieces of advice allowing the shooting of the document to be improved.
[0060] In the opposite case when textual and graphical information extracted from the image of the document, and then corrected, is deemed to be legible or interpretable by a character or pattern recognition software package, the server S will be able to transmit a warning message to the communications terminal TC or to the terminal T.
[0061] Advantageously, in the event of the server S having received an acknowledgment of receipt of the fax or email transmission of the digitized document to the addressee DES, the server S will be able to transmit an acknowledgment of receipt message to the communications terminal TC or to the terminal T.
[0062] Advantageously, transfer of the image or of information relative to the document will be performed via a wire connection such as the series or USB link or a wireless connection such as 802.11, Wimax, or Bluetooth, or a wired, switched, ADSL, communications network, or a cellular network such as GSM, GPRS or UMTS, or a local network such as an intranet, or a non-local network such as Internet. | The method according to the invention comprises the capture and storage of an image of a document by means of a camera optionally integrated into a communications terminal, with transfer of the image into the memory of the terminal, transmission of the image associated with complementary information by the terminal to a server, extraction, correction and optionally interpretation by the server of document-related information contained in the image, reconstruction of the document by means of extracted, corrected and optionally interpreted information and archiving of the document, taking into account information contained in the reconstructed document. | 7 |
FIELD OF THE INVENTION
The invention relates to installations for continuously treating a strip product such as a film, web, cloth, or other fiber or non-fiber thin substrate.
A particular field of application of the invention is continuously treating strip products in a furnace in order to form a deposit thereon, to perform surface treatment thereon, or to perform carbonization thereof. The invention relates particularly, but not exclusively, to continuously carbonizing fiber substrates such as cloth or web made of fiber or yarn.
BACKGROUND OF THE INVENTION
Installations are known for producing carbon fiber cloth by continuously carbonizing cloth made of carbon-precursor fibers. Reference can be made in particular to Russian patent No. RU 2 005 829.
The cloth to be carbonized, e.g. made of cellulose fibers, travels continuously through a furnace in which the carbon precursor is transformed by pyrolysis so that a carbon fiber cloth is recovered continuously from the outlet of the furnace.
Pyrolysis is performed under an inert atmosphere by injecting a gas, e.g. nitrogen, into inlet and outlet zones at the ends of the furnace. The inert gas is extracted together with the effluent of the pyrolysis via chimneys leading away from various zones of the furnace.
The inside of the furnace must be sealed so as to be sure that no pyrolysis effluent can escape to the outside through the inlet or the outlet of the furnace and so as to ensure that no air can penetrate into the inside of the furnace. Effluent escaping from the inlet or the outlet of the furnace would not only make it more difficult to eliminate the effluent, but would also pollute the cloth by allowing tars conveyed by the effluent to condense or deposit thereon. Air penetrating into the furnace would oxidize the cloth and, by cooling the product could also give rise to undesirable condensation of pyrolysis effluent.
Good sealing can be provided by pressing a lip or a roller against the cloth. Nevertheless that can sometimes lead to high levels of friction, thereby inducing tension in the cloth. However, during carbonization, the cloth can shrink considerably. It can shrink substantially freely in the weft direction, but tension applied by friction, e.g. using rollers, prevents shrinkage from taking place freely in the warp direction. This results in excessive weft deformation in the resulting cloth.
Good sealing can also be provided by a dynamic seal formed by a flow of inert gas, such as a nitrogen seal. Nevertheless, that would disturb the aerodynamics inside the furnace and would also cool the pyrolysis effluent, thereby leading to the above-mentioned drawbacks. In addition, such a solution is unsuitable when particular pressure conditions need to be maintained inside the furnace.
OBJECT AND SUMMARY OF THE INVENTION
An object of the invention is to remedy those drawbacks, and more generally, to provide a sealing box for an enclosure for continuously treating a strip product while providing excellent sealing:
without disturbing the internal aerodynamics of the enclosure;
while maintaining the inside of the enclosure at a desired pressure; and
without exerting tension on the strip product that could lead to its behavior or its appearance being disturbed.
According to the invention, this object is achieved by a sealing box comprising:
a longitudinal passage opening out from the box via a first end for connection to an inlet or an outlet of the enclosure, and via a second end, opposite from the first;
a support surface inside the passage, on which a strip product can travel between the ends of the box; and
static sealing means acting by coming into contact with the strip product travelling along the passage on the support surface;
in which box, according to the invention:
the static sealing means comprise at least one inflatable gasket placed across the passage, above the support surface; and
dynamic sealing means are also provided in the passage between the second end of the box and the static sealing means, the dynamic sealing means comprising means for injecting gas into at least one chamber formed in the passage.
The combination of static sealing means and of dynamic sealing means makes it possible to use static sealing means that exert minimum friction force on the travelling strip product. Thus, the inflatable gasket is preferably inflated to a pressure that exceeds atmospheric pressure by less than 500 Pascals (Pa). It is also made of a material over which the thin products can slide with a minimum amount of friction, e.g. a silicone-coated cloth.
Thus, with a sealing box of the invention, it is possible to limit the tension exerted on the travelling strip product. For a strip product in the form of a cloth that is subjected to carbonization inside the enclosure, the difference between the substantially free shrinkage in the weft direction (expressed as a percentage) and the shrinkage in the warp direction (also expressed in percentage) can be restricted to a value of less than 5%.
The dynamic sealing means advantageously comprise means for injecting gas into a chamber defined by the inflatable gasket and a wall extending across the passage. The dynamic sealing means preferably comprise a plurality of adjacent chambers separated from one another by walls extending across the passage, each chamber being provided with its own gas injection or extraction opening. In this configuration, an extraction chamber is situated between two injection chambers.
Advantageously, the or each wall defining a chamber is provided with a flexible bib at its end adjacent to the path of cloth along the passage, e.g. a bib of silicone-coated cloth. The bib does not perform a static sealing function, and as a result it does not exert any significant force on the strip product travelling along the passage.
According to a feature of the invention, the inflatable flexible gasket is made up of a plurality of adjacent sections aligned side-by-side across the passage, each section being provided with its own inflation means so as to make it possible to adjust the inflation pressure in each section of the gasket independently.
As a result, it is possible to exert a force that varies in the transverse direction on the strip product. When the strip product is cloth that is being subjected to carbonization, that makes it possible to control straightness of grain by compensating for the cloth shifting out of register during carbonization, i.e. for the deformation to which the cloth is subject by weft curvature.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood on reading the following description given by way of non-limiting indication and with reference to the accompanying drawings, in which:
FIG. 1 is a highly diagrammatic view of a portion of an installation for continuously carbonizing cloth;
FIG. 2 is a longitudinal section view through an embodiment of a sealing box of the invention for the furnace of the FIG. 1 installation;
FIG. 3 is a fragmentary cross-section view on plane III—III of FIG. 2;
FIG. 4 is a fragmentary view of cloth that is out of register; and
FIG. 5 is a highly diagrammatic cross-section view of a variant embodiment of an inflatable gasket in a sealing box of the invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
In the description below, an embodiment of the invention is described in its application to continuously carbonizing cloth. As stated above, the invention is nevertheless applicable more generally to any strip product which is treated continuously in an enclosure. The term “strip product” is used herein to mean a product such as a film, or a thin substrate, optionally made of fibers. In addition to cloth, fiber substrates can be constituted by unidirectional or multidirectional fiber webs. In addition, the invention is more generally applicable to strip products that are to be subjected to various types of treatment in an enclosure, for example having deposits formed thereon, being subjected to surface treatment, or to physical or chemical transformation, whenever there is a need more particularly to avoid applying any significant tension to the strip product and to avoid disturbing the aerodynamic and pressure conditions inside the enclosure.
In the installation shown very diagrammatically in FIG. 1, a cloth T is carbonized by travelling continuously through a furnace 1 . The cloth T, which has possibly been subjected to pre-treatment, is taken from a receptacle in which it was previously stored, for example in a loose pile.
The cloth T is made of carbon-precursor fibers, e.g. cellulose fibers. The pre-treatment of the cloth can consist in being impregnated with an organo-silicon compound enabling good mechanical properties to be conserved for the carbonized cloth. One such pre-treatment is described in particular in Russian patent No. RU 2 047 674.
The furnace 1 has a pyrolysis chamber 2 whose walls are made of graphite, for example, which chamber is received inside casing 3 . The cross-section of the chamber 2 is in the form of a flat rectangle defining a passage for the cloth between a furnace inlet 1 a and a furnace outlet 1 b . Heating resistance elements 4 are placed on the outside faces of the top and bottom walls 2 a , 2 b of the pyrolysis chamber 2 inside the casing 3 . Several sets of heating elements can be distributed in the longitudinal direction so as to define a succession of zones within the pyrolysis chamber that can be raised to different temperatures.
Pipes 5 , 6 serve to feed the inside of the pyrolysis chamber 2 with an inert gas such as nitrogen in the vicinity of the longitudinal ends 1 a , 1 b of the furnace 1 . The neutral gas, together with the gaseous pyrolysis effluent are extracted from the pyrolysis chamber via chimneys 7 distributed along the furnace 1 .
The travel of the cloth through the furnace is controlled by a puller device 8 at the outlet from the furnace, and the resulting carbon fiber cloth is stored, for example by being wound on a reel 9 . Carbonizing the cloth leads to a large amount of shrinkage, that can be as much as about 30% when using a cellulose precursor cloth that is carbonized while in the free state, without any tension being applied thereto. There therefore exists a relatively large difference in cloth speed between the inlet and the outlet of the furnace.
Sealing boxes 10 , 11 have the cloth passing through them and are placed respectively at the inlet and at the outlet of the furnace 1 so as to prevent external air penetrating into the furnace and pyrolysis effluents from escaping from the furnace.
A furnace for continuously carbonizing cloth as briefly outlined above is known, e.g. from Russian patent No. RU 2 005 829.
An embodiment of the sealing box 10 situated at the inlet to the furnace 1 and in accordance with the present invention is described below in greater detail with reference to FIGS. 2 and 3.
The box 10 defines a longitudinal passage 12 for the cloth T between an end 12 a that is upstream in the cloth travel direction, and a downstream end 12 b . At the downstream end, the passage 12 is connected to the inlet of the pyrolysis chamber 2 of the furnace.
In the example shown, the box 10 is formed by a base or anvil 14 which defines a horizontal support surface 14 a for the cloth travelling through the passage 12 , and by a cover 16 having a top wall 16 a and side walls 16 b which define the passage 12 . At its downstream end, the cover has an end wall 18 which co-operates with the base 14 to define an outlet slot 20 through which the cloth leaves the box 10 . The end wall 18 extends above the cover 16 and is connected via a horizontal axis hinge 22 to the casing 3 . A sealing gasket 19 is compressed between the wall 18 and the casing 3 when the cover 16 is closed. The base 14 has a rim 14 b at its downstream end fixed to the casing 3 with a sealing gasket 15 being interposed therebetween. The sealing box 10 contains static sealing means 30 and dynamic sealing means 40 .
The static sealing means 30 comprise an inflatable gasket 32 which extends across the passage 12 in the vicinity of the downstream end 12 b . The gasket 32 is formed by a strip of flexible material fixed along its edges to a base member 34 and co-operating therewith to define a volume 36 . The base member 34 is itself fixed to the cover 16 with a sealing spacer 35 being interposed between them. The gasket 32 can be preinflated, or it can be provided with an inflation gas feed pipe 38 , e.g. for feeding nitrogen.
The pressure of the gasket 32 on the cloth T travelling over the support surface 14 a must be limited, as must the friction between the gasket and the cloth so as to avoid imparting tension forces to the cloth which, because of the large amounts of shrinkage during carbonization, could give rise to excessive deformation of the weft yarns in the resulting carbon fiber cloth.
For this purpose, the pressure in the gasket 32 , i.e. inside the volume 36 , exceeds atmospheric pressure by an amount that is less than 500 Pa, and that preferably lies in the range 0 Pa to 50 Pa. When the cover is closed, the gasket 32 flattens out onto the cloth T (FIGS. 2 and 3 ). In addition, the material from which the gasket is made is selected so as to minimize friction with the cloth. By way of example, it can be made of a silicone-coated cloth. Other materials could be used, such as cloth coated in polytetrafluoroethylene or an elastomer membrane, e.g. a silicone membrane.
In the example shown, the dynamic sealing means 40 comprise chambers 42 , 44 , 46 situated in the passage 12 between its upstream end 12 a and the inflatable gasket 32 .
An inert gas, e.g. nitrogen, is injected into the chambers 42 and 46 via respective pipes 52 , 56 passing through the cover 16 and opening out into the passage 12 . The inert gas is extracted from the chamber 44 situated between the chambers 42 and 46 by means of a suction pipe 54 passing through the cover 16 and opening out into the passage 12 .
The chambers are defined by metal walls 62 , 64 , 66 which extend across the passage 12 . The wall 62 is situated close to the upstream end 12 a and co-operates with the wall 64 to define the injection chamber 42 . The extraction chamber 44 is defined by the walls 64 and 66 , while the injection chamber 46 is defined by the wall 66 and the gasket 32 .
The walls 62 , 64 , 66 are fixed to the cover 16 and they are applied in leaktight manner thereto along their top edges. Along their bottom edges, the walls 62 , 64 , 66 are provided with respective bibs 72 , 74 , 76 which just touch the surface of the cloth T. The bibs 72 , 74 , 76 are made of a material that is identical or similar to that of the gasket 32 , e.g. a silicone-coated cloth. It should be observed that the bibs 72 , 74 , 76 do not exert any pressure on the cloth T and therefore do not impart any tension therein.
The chambers 42 , 44 , 46 provide an effective barrier to outside air entering. The inert gas injected into the chamber 46 adjacent to the inflatable gasket 32 is taken up by the extraction chamber 44 . If a small fraction of this gas should reach the static gasket 32 it is not sufficient to disturb the flow of gases in the pyrolysis chamber and is merely added to the gas that is inserted via the pipe 5 . The chambers 42 and 46 are preferably fed with inert gas at a rate that constitutes less than 10% of the total rate at which gas is injected into the furnace via the pipes 5 and 6 .
Although the dynamic sealing means are described as being made with an inert gas extraction chamber situated between two injection chambers, other configurations are possible, for example it is possible to add one or more pairs of injection and extraction chambers, or to make do with a single injection chamber 46 , the inert gas then being extracted through the inlet 12 a of the passage 12 .
Advantageously, the inflatable gasket 32 is protected from the radiant heat coming from the pyrolysis chamber 2 at the inlet to the furnace. For this purpose, one or more heat screens 80 extend across the end of the passage 12 . By way of example, the screens 80 can be sheets of graphite fixed to the end wall of the cover, on the outside, with insulating spacers 82 being interposed between them, e.g. spacers made of ceramic.
At its downstream end, the box 10 engages in the upstream end of the pyrolysis chamber 2 via cross-bars 84 , 86 of thermally insulating material, e.g. of ceramic or of refractory metal, which are fixed on the outside faces of the wall 18 and of the rim 14 b and which engage between the top and bottom walls 2 a , 2 b of the chamber 2 .
In the example shown, the sealing box 10 is in the form of a base surmounted by a pivoting cover. The cover can be driven by means of actuators 24 . This disposition gives easy access to the passage 12 at the beginning of a carbonization cycle in order to insert the end of the cloth T. Naturally, other embodiments of the box could be provided, e.g. having a screw-on cover.
The description above relates to a sealing box 10 situated at the inlet of the furnace. The sealing box 11 situated at the outlet of the furnace can be made in similar manner, adopting a disposition that is symmetrical to that of the box 10 relative to the middle of the path followed by the cloth T through the furnace. Under such circumstances, the static inflatable sealing gasket in the box 11 is situated close to the outlet from the furnace, i.e. in the vicinity of the upstream end of the box 11 which is connected to the outlet from the furnace, while the dynamic sealing means are disposed downstream from the inflatable gasket.
The application of pressure to the cloth in the sealing box 11 is less critical than it is in the sealing box 10 since the cloth leaving the furnace has already been subjected to shrinkage. The static sealing gasket of the box 11 could therefore be constituted, in a variant, as a conventional roller or bib, and the dynamic sealing means could be omitted.
A continuous carbonizing installation with sealing boxes at the inlet and at the outlet of the furnace, of the type shown in FIGS. 3 and 4, has been used for carbonizing rayon cloth having a satin weave. The pressure in the static inflatable sealing gasket was set to 10 Pa above atmospheric pressure. The low tension induced in the cloth gave rise to shrinkage in the warp direction of 27% whereas shrinkage in the weft direction was substantially equal to the maximum potential for shrinkage exhibited by the cloth under no tension, being about 30%.
A variant embodiment of the sealing box 10 at the inlet to the carbonizing furnace is described below with reference to FIGS. 4 and 5.
FIG. 4 shows a particular type of deformation that can occur in the cloth T′ of carbon fibers, due to lack of uniformity in the temperature of the furnace in the transverse direction, i.e. across the width of the furnace, or due to non-uniform shrinkage of the cloth during carbonization, or due to poor quality stitching for joining widths of cloth together. Such out-of-register deformation gives rise to the weft t of the cloth being deformed.
It is possible to correct this deformation in order to reestablish a straight grain for the cloth by braking certain portions of the warp of the cloth (not shown in FIG. 4) more than other portions, prior to allowing the cloth to enter into the furnace. The warp portions that are subjected to greater braking are subjected to less shrinkage, which can compensate for weft deformation.
Differential action can be applied to the warp portions of the cloth by means of a sealing box which differs from that shown in FIGS. 2 and 3 in that the static sealing means are constituted by an inflatable gasket 132 (FIG. 5) that is subdivided into a plurality of adjacent sections 132 1 , 132 2 , . . . , 132 6 forming a line extending in the transverse direction. Each gasket segment is fed with inflation gas via a particular respective feed pipe 138 1 , 138 2 , . . . , 138 6 passing through the cover 16 . By selectively controlling the pressures in the sections of the gasket, adjustable amounts of force are applied to different portions of the warp of the cloth T travelling over the base 14 . The pressures are adjusted on the basis of the registering error, if any, observed on the cloth leaving the furnace.
Such means for controlling the straightness of the grain of the carbon fiber cloth are particularly advantageous in terms of simplicity and bulk, when compared with well-known systems using sets of bias rollers and curved rollers that are servo-controlled in position and in rotation. | A sealing box for a chamber for continuously treating a thin strip product, in particular for a furnace for continuously carbonizing a fiber substrate.
The sealing box comprises: a longitudinal passage ( 12 ) opening out from the box via a first end ( 12 b ) for connection to an inlet or an outlet of a treatment chamber ( 2 ) and via a second end ( 12 a ), opposite from the first; a support surface ( 14 a ) inside the passage, on which a strip product (T) can travel between the ends of the box; and static sealing means ( 30 ) acting by making contact with the strip product travelling along the passage on the support surface. The static sealing means comprise at least one inflatable gasket ( 32 ) placed across the passage ( 12 ) above the support surface ( 14 a ), and dynamic sealing means ( 40 ) are also provided in the passage between the second end ( 12 a ) of the box and the static sealing means, the dynamic sealing means comprising means ( 52, 56 ) for injecting gas into at least one chamber ( 42, 46 ) formed in the passage. The sealing box is suitable in particular for a furnace that produces carbon fiber cloth by continuously carbonizing a cloth made of a carbon precursor. | 3 |
BACKGROUND AND SUMMARY OF THE INVENTION
The present invention relates generally to barbecue grills and more particularly to an electronically controlled barbecue grill employing a microprocessor-based electronic circuit for monitoring fuel status, cooking time and temperature and for monitoring and controlling electronic ignition. The electronic circuit includes a human-readable display and comprises a compact and fully integrated, battery-powered control package which affords great convenience and high reliability.
One popular style of conventional barbecue grill in use today employs a containment casting with a gas burner assembly disposed therein and supplied with fuel stored under pressure in a replaceable or refillable canister. Typically, a manually adjustable fuel supply valve is interposed between canister and burner to allow the user to adjust the height of the flame and the cooking temperature. Normally a mating lid is hingedly attached to the casting for use in covering the grill cooking surface and for defining an oven space beneath the lid and within the casting. Some barbecue grills of this type have an analog thermometer of the bimetal type attached to the lid to allow the user to determine the temperature within the oven space, when the lid is closed. In addition, some models may include a push-button operated electronic ignition. In use, the user adjusts the gas valve to establish fuel flow into the burner and then depresses the electronic ignition button, causing a momentary spark to ignite the fuel at the burner.
The present invention affords a great deal of convenience not found in conventional barbecue grills. The invention employs a microprocessor-based electronic circuit which monitors and controls various functions of the grill.
A canister weighing system with electronic output provides the data used by the microprocessor to determine the quantity of fuel remaining. The microprocessor displays the quantity of fuel remaining either as a numerical fractional value, or in terms of remaining burning time, based on a calculation performed by the microprocessor. The electronic circuit also includes means for user input of a desired cooking time. The microprocessor circuit includes a real time clock for comparison with the desired cooking time to provide an alarm when the desired cooking time has elapsed. In addition, the desired cooking time is compared by the microprocessor with the remaining burning time for the fuel within the canister. If the microprocessor determines that the fuel remaining in the canister is insufficient to complete the desired cooking time, a notification of the low fuel condition is automatically displayed when the desired cooking time is first entered. This provides the user ample opportunity to fill or replace the fuel canister before beginning to cook. The microprocessor also automatically warns of a low fuel condition when the quantity of fuel drops below 1/8 of the full level.
The electronic circuit also includes an automatic electronic ignition control which may be initially activated by the user, simply by turning the gas supply valve to its fully on position. A first ignition event occurs in response to manual actuation, causing the electronic ignition device to be actuated. An electronic flame sensing device monitors whether a flame is produced in response to the ignition event. If a flame is not present after the first ignition event, the electronic circuit automatically causes one or more subsequent ignition events to occur, without further human interaction, in an effort to ignite the burner. After a predetermined number of attempts at ignition, if no flame is produced, an error message is displayed and an audible alarm is sounded to allow the user to correct the problem or attempt to light the burner manually with a match.
The same flame sensing apparatus continues to monitor the flame even after ignition and the electronic circuit automatically initiates a reignition cycle if the flame is extinguished. This might occur, for example, if a strong wind were to blow out the flame.
Anytime the electronic circuit is unable to ignite or reignite the flame after a predetermined number of tries an error message is displayed, giving the most likely cause of the problem, the principal reasons being inadequate fuel or insufficient battery energy to cause an ignition spark. Accordingly, the control circuit monitors fuel level and battery voltage to provide the appropriate "Fuel Out" and "Low Battery" messages.
The electronic control circuit also employs a thermistor sensor attached to the mid-rear portion of the lower containment casting. The thermistor provides an electrical signal indicative of the cooking temperature. The microprocessor-based control circuit can display the temperature on the integral display device located on the front console. This same display device is also used to display the fuel status messages, electronic timer messages and error messages, when appropriate.
In one user-selected mode the microprocessor cycles various information onto the display device in a rotating sequence. In this fashion, fuel level, fuel time, cooking temperature and cooking time are sequentially displayed.
For a more complete understanding of the invention, its objects and advantages, reference may be had to the following specification and to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a barbecue grill in accordance with the invention;
FIG. 2 is a fragmentary rear view of the grill, showing placement of the temperature sensor thermistor;
FIG. 3 is a partial horizontal cross-sectional view illustrating the presently preferred weighing mechanism for determining fuel quantity;
FIG. 4 is a top view of the burner assembly, illustrating placement of the electronic ignition and flame sensing package;
FIG. 5 is a cross-sectional view taken substantially along the line 5--5 of FIG. 4, illustrating the ignition and flame sensing package and its relationship to the burner assembly in greater detail;
FIG. 6 is a cross-sectional view taken substantially along the line 5--5 of FIG. 5, illustrating yet another view of the ignition and flame sensing package;
FIG. 7 is an electronic circuit diagram of the control circuit of the invention;
FIG. 8 is a flow chart describing the master control loop executed by the microprocessor in implementing the invention;
FIG. 9 is a flow chart depicting the function of the Display button in accordance with the invention;
FIG. 10 is a flow chart illustrating the function of the Set Time button in accordance with the invention;
FIG. 11 is a flow chart describing the electronic ignition sequence.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, a grill in accordance with the invention is illustrated generally at 18. The grill comprises a lower containment casting 20, an upper hingedly attached lid 22 and preferably a supporting framework 24 on which the lower casting rests. Secured to the framework generally beneath casting 20 is a console 26 behind which many of the components of the electronic grill control circuitry are located. Visible on the front of console 26 is an alphanumeric display on which human-readable information may be displayed. In the presently preferred embodiment this display 28 comprises a liquid crystal display, although other types of displays are also usable. To the left of display 28 is the "Display" push-button 30 and to the right is "Set Time" push-button 32. Preferably bush-buttons 30 and 32 are implemented using membrane switches. The functions of these push-button will be described below.
Also positioned on console 26 are the fuel supply valves 34 and 36. The embodiment illustrated employs a burner having left and right portions which are independently controllable by valves 34 and 36, respectively. Turning the right valve 36 to its fully on (fully clockwise) position initiates the flame ignition sequence described below.
Fuel source canister 38 is disposed beneath casting 20 and generally within the confines of framework 24, as illustrated. Fuel source canister 38 rests upon a generally horizontal supporting platform 40. This platform is hingedly attached to the generally horizontal mounting plate 42 in turn supported by framework 24. Platform 40 is hingedly attached to plate 42 for pivotal movement about an axis generally parallel with the innermost front-rear extending edge 44 of platform 40.
With momentary reference to FIG. 3, the canister 38 and platform 40 are illustrated in greater detail, showing the outermost front-rear edge 46. As illustrated, platform 40 has a downturned flange 48 with outwardly extending bracket 50. Plate 42 is also provided with a bracket in generally vertical alignment with bracket 50. A bias spring 54 is secured between brackets 50 and 52, serving to support edge 46 of platform 40 so that platform 40 is generally horizontal.
The spring-loaded platform serves as a weighing scale wherein the weight of canister 38 and any fuel contained therein acts against the bias spring force of spring 54. Depending on the weight of the canister and fuel, edge 46 will be displaced relative to the plate 42, the amount of displacement being proportional to the combined weight of the canister and fuel. A linear slider-type potentiometer 56 is coupled via linkage 58 to bracket 50. Thus the amount of displacement of the edge 46 relative to plate 42 may be related to the potentiometer slider setting. By applying a voltage and measuring the voltage drop across potentiometer 56, the amount of displacement, and hence the combined weight of canister and fuel can be determined and made available to the microprocessor circuit. Linkage 58 may either be pivotally connected or slidably connected between potentiometer slider and bracket 50 to allow for the slight arcuate trajectory of bracket 50 as it rotates about the pivotal axis.
Referring now to FIG. 2, the presently preferred location of temperature sensing thermistor 60 is illustrated at the rear side of lower casting 20, generally in the middle near the top rim thereof.
FIG. 4 illustrates the burner assembly 62 in relation to the casting floor 64. The ignition and flame sensing package 66 is also illustrated in the presently preferred position. As seen in FIGS. 5 and 6, the ignition and flame sensing package comprises a pair of spaced-apart and generally parallel electrodes, namely first electrode 68 and second electrode 70. Both electrodes pass through an aperture 72 in casting floor 64. Both are provided with ceramic insulators 74. Both ceramic insulators are secured to an elongated U-shaped protective cover by means of ferrules 78. Electrodes 68 and 70 includes portions which are generally parallel to the edge 80 of burner 62.
During an ignition event a high voltage potential is developed between electrodes 68 and 70, causing a spark to jump between the electrodes to ignite the fuel emanating from burner 62. Typically, the electrical potential difference between electrodes is on the order of 20,000 volts. The dual electrode ignition system employed by the invention represents a significant improvement over single electrode systems, particularly since the ignition system is used in conjunction with a microprocessor control circuit.
In single electrode systems a voltage potential is developed between the electrode and the burner, which is grounded to the casting. The casting, however, is not fully grounded, since the supporting framework may be resting upon nonconductive plastic or rubber wheels, or upon nonconductive wooden patio decks for example. The effect of a 20,000 volt ignition spark causes transient electrical impulses or voltage spikes to undesirably appear in the microprocessor power supply. Such impulses or spikes present a significant problem in that they can damage delicate electronic circuitry and can cause the microprocessor to incorrectly process information, frequently resulting in a lock-up condition in which the battery power must be completely removed and then re-established in order to bring the microprocessor circuit back into operation.
The present invention employs a dual electrode ignition system in which the spark is caused to jump from one electrode to the other, rather than from one electrode to the chassis ground. Both electrodes are heavily isolated from the microprocessor power supply, thereby effectively eliminating unwanted voltage spikes, impulses or other transients.
The ignition and flame sensing package 66 also functions to sense the presence or absence of flame at the burner. This is accomplished by measuring the relative impedance of the air space in the vicinity immediately adjacent the burner jets. The burner jets are indicated at 82 in FIG. 5. Flame sensing is accomplished by applying a known reference voltage to electrode 70 and by then measuring with an impedance bridge the amount of conductance between electrode 70 and the burner 62. When no flame is present the impedance is quite high, resulting in no conductance between electrode 70 and burner 62. However, with a flame present the gaseous constituents of combustion, principally ions, serve to significantly lower the impedance and permit conductance between electrode 70 and burner 62. Accordingly, when no flame is present the voltage on probe 70 will be equal to the fixed reference voltage. With a flame present the voltage at probe 70 will drop appreciably, approaching the potential (ground) at burner 62. This voltage drop is monitored by the electronic control circuitry to derive a flame signal indicative of the presence or absence of flame.
Referring now to FIG. 7, the electronic circuit of the invention is illustrated in schematic block diagram form. The presently preferred embodiment utilizes a microprocessor-based circuit and may be implemented using any one of a number of commercially available microcontrollers.
With reference to FIG. 7, the microprocessor-based circuit includes a microprocessor or CPU 84 to which random access memory RAM 86, read-only memory ROM 88 and an audible annunciator or speaker 87 are attached. The microprocessor 84 is coupled to alphanumeric display 28 via a display driver 112. Four analog to digital conversion channels are used to handle input data from the fuel weighing mechanism (A to D converter 90), from the temperature thermistor (A to D converter 92), from the flame presence sensor (A to D converter 94) and from the battery voltage monitor (A to D converter 95). The circuit is powered by a battery of suitable voltage, preferably a 9 volt battery 96. If necessary the battery 96 may be supplemented with appropriate voltage doubling circuits and voltage regulator circuits (not shown) in order to provide different supply voltages as may be required for a particular microprocessor or for a particular alphanumeric display 28. For purposes of explaining the principles of the invention, a simple 9 volt power supply employing battery 96 has been illustrated.
In accordance with conventional practice CPU 84 is attached to an external timing source such as crystal 98. This timing source is used to maintain a stable clock for microprocessor operation. The CPU 84 uses this clock to derive a suitable timer clock for measuring elapsed cooking times and for controlling other cyclic operations of the master control program stored in ROM 88.
The fuel level sensor, as explained above, relies upon weighing of the canister and fuel. In FIG. 7 the spring-loaded weighing mechanism is indicated generally at 100. The weighing mechanism is connected to potentiometer 56 as previously described. This potentiometer is in turn connected to a calibration potentiometer 102 and the output of calibration potentiometer 102 is supplied to A to D converter 90. In use, an empty canister is placed on weighing mechanism 100 and calibration potentiometer 102 is adjusted to produce an "Empty" reading on display 28. This setting of potentiometer 102 calibrates the system by providing microprocessor 84 with a reference voltage indicative of an empty canister.
Thermistor 60 is attached to A to D converter 90 for providing an indication of the temperature. As illustrated, the thermistor is coupled to a suitable pull-up resistor 94 such that thermistor 60 and pull-up resistor 94 act as a voltage divider network, with the output voltage being indicative of temperature.
A similar arrangement is provided for flame sensing. The flame sensing probe 70 is illustrated in spaced relation to the burner assembly 62, which is grounded as at 106. A pull-up resistor 108 is attached to analog to digital converter 94 along with probe 70. When the impedance between probe 70 and burner 64 is high (flame absent) the voltage applied to analog to digital converter 94 is at a high level. With a flame present, ionization of the gaseous constituents of the flame causes the impedance between probe 70 and burner 62 to drop, thereby substantially lowering the voltage applied to analog to digital converter 94. This change in voltage is sensed by microprocessor 84 and used as an indication of the presence or absence of flame. Although an analog to digital converter 94 is used in the illustrated embodiment, the presence and absence of flame is a sufficiently digital (yes/no) concept that the analog to digital converter may be dispensed with if the additional analog to digital converter is not readily available on the selected microcontroller package being used. In this instance, the analog to digital converter may be eliminated with line 110 being supplied directly to one of the data inputs of microprocessor 84.
In order to provide the electronic ignition control, microprocessor 84 is coupled to a high voltage generator circuit 114, such as a capacitor discharge circuit or flyback circuit. Specifically, microprocessor 84 is coupled to the high voltage circuit by means of an address decoder circuit 116. The address decoder circuit monitors the address bus of the CPU. When a predefined address is placed on the address bus, decoder 116 detects this and outputs a control signal on line 118. The control signal is an on/off signal which triggers the high voltage circuit, causing approximately 20,000 volts to be placed across probes 68 and 70.
Commands from the user are input via push-buttons 30 and 32. The ignition signal is provided by ignition switch 36A, which is mechanically integrated with supply valve 36 to operate when that valve is turned fully on. All switches communicate with microprocessor 84 via its data input bus.
The software program under which microprocessor 84 operates is illustrated in FIGS. 8, 9, 10 and 11. These software program routines are stored in ROM 88. Any variables such as elapsed time and temperature are stored in system RAM 86. Software flags which store binary (yes/no) settings are also stored in ROM 88. These variables and flags are listed in Table I below. In essence, the microprocessor 84 is preprogrammed to execute a never-ending loop or circular queue of program instructions, designated generally as the Master Loop, illustrated in FIG. 8. With reference to FIG. 8, the Master Loop performs a series of different functions, one after the other, in a cyclical fashion. Although these functions have been designated in a particular sequence in FIG. 8, it will be understood that the order is not generally significant and that other sequences are also possible in implementing the invention.
TABLE I______________________________________Variables Flags______________________________________1. Time 1. Low Battery2. Fuel Level 2. Flame Presence3. Temperature 3. Set Timer - Cycle Fast4. Display Button State 4. Ignition Switch Closed (a) Fuel in Tank (b) Hours in Tank (c) Timer Setting (d) Temperature (e) Scan Display______________________________________
Referring to FIG. 8, the Master Loop cycles through a series of "Monitor" steps, such as monitor time 200, monitor battery 202, monitor temperature 204, monitor flame 206, monitor push-buttons 208 and monitor fuel 209. In essence, these Monitor steps are the data input steps performed by microprocessor 84. The monitor time routine, for example, updates a running clock value stored in RAM memory which is used to determine the elapsed cooking time. As will be explained in connection with the set time button, the user inputs a desired cooking time in terms of hours and minutes. This value is stored in memory as a variable. The monitor time routine decrements the stored value in accordance with the number of internal clock cycles that have elapsed since the last time variable update. In this regard, microprocessor 84 has the conventional capability to maintain an accurate elapsed time clock by dividing the CPU by an appropriate number to obtain minutes and hours.
The monitor battery step utilizes analog to digital converter 95 to measure the battery voltage and to determine whether the battery is below a predetermined appropriate operating voltage. If the monitor battery step determines that the voltage is low, a low battery flag is set in RAM 86 for use by the display handling routine described below.
The monitor temperature routine likewise monitors the output of thermistor 60 and stores a digital numerical value indicative of the measured temperature in a variable in RAM 86.
The monitor flame step 206 similarly monitors the voltage drop between probe 70 and ground, as discussed above. A flame presence flag is set or reset in RAM 86 depending upon whether the burner is lit or not.
The monitor buttons routine 208 polls both Display button and Set Time button to determine whether the user has depressed either. Because the Master Loop operates at a sufficiently high speed, the monitor buttons routine 208 occurs with such rapid frequency that microprocessor 84 appears to respond to the button depress with no apparent delay. The monitor buttons functions are further described in the flowcharts of FIGS. 9 and 10 discussed below. Essentially, however, the data input by the user depressing these buttons causes information to be stored in a display button state variable comprising five individual flags, one for each button state in RAM 86 for use by the remainder of the Master Loop program.
The monitor fuel routine 209 is similar to the monitor temperature routine, in that the fuel level is determined via potentiometer 56 reading and stored as a fuel level variable in RAM 86.
The Master Loop program, in addition to handling data input, also controls the functioning of the electronic grill control in accordance with the data that have been input. For example, the Master Loop includes a light burner routine to 10 which is responsible for causing ignition events to occur. The light burner routine is described more fully via FIG. 11 and is further discussed below. As will be described, the light burner routine accesses the flame lit flag which is set and reset by the monitor flame routine 206.
Similarly, the output to display routine 212 is responsible for providing the appropriate message on alphanumeric display 28. In the event of an error condition resulting from the burner failing to light, routine 212 will display the appropriate message indicating the most likely reason for failure, such as low battery or low fuel. Absent an error condition, the output to display routine 212 displays the data selected by the user for display. The user having made a selection which is handled by the monitor buttons routine 208, the output to display routine will display the desired parameter such as fuel remaining in tank, hours remaining in tank, timer setting, temperature, or a scan among all of these.
In the event of error conditions described above an audible alarm is produced through speaker annunciator 87. The output to this audible alarm is performed by step 214, which monitors the flame lit flag to alert the user when the flame has failed to light after the predetermined number of ignition attempts or in the event the flame is blown out. In addition, as a further convenience to the user, the output to audio routine 214 also monitors the temperature variable and sounds a predetermined tone when the temperature reaches 400° F., the presently preferred preheating temperature. This preheating tone alerts the user when the grill is sufficiently warmed up to begin most grilling processes.
Referring now to FIG. 9, the display button routine which forms a portion of the monitor buttons routine 208 is illustrated. Essentially, each time the user depresses the display button, the display mode steps from one mode to the next. For example, if the system commences in a mode displaying the quantity of fuel remaining in the tank (step 216), depressing the display button once will cause the mode to shift to step 218 where the hours of burning time remaining in the tank are displayed. Depressing the display button again displays the timer setting at step 220. Depressing the button once again displays the temperature at step 222. When the button is again depressed a scan mode 224 is entered. In the scan mode the output to display routine 212 causes the display to cycle sequentially, displaying fuel in tank, hours in tank, timer setting and temperature.
Each time the user depresses the display button a display flag in RAM is altered to indicate which of the five display modes has been selected. The output to display routine 212 reads this flag in order to determine which display to provide, subject to an error message override.
The set time button is similar in operation. Depressing the button briefly causes the desired cooking time to increase from 0 to a maximum of 9 hours and 59 minutes in 1 minute intervals. Depressing the set time button momentarily causes the time to increment in 1 minute intervals. Holding the set time button down for a predetermined longer duration causes the time to be incremented at a faster rate. FIG. 10 depicts the slow cycle and fast cycle times at steps 226 and 228.
Referring to FIG. 11, the ignition sequence routine is illustrated. The ignition sequence commences at step 250 by checking the ignition switch closed flag to determine whether it is appropriate to commence an ignition sequence. If the ignition flag indicates that the ignition switch is not closed, the program does nothing further. However, if the ignition switch closed flag has been set, program control continues in step 254 by setting a "tries counter" to 0 in step 254. This tries counter keeps track of how many attempts at ignition have been made. Next in step 256 the actual ignition event is initiated. Microprocessor 84 causes a predetermined address to be placed on the address bus which is decoded by address decoder 116. The decoded address provides a logic signal on line 118, causing the high voltage circuit 114 to generate a spark.
Next in step 258 the program tests the flame presence flag to determine whether the ignition sequence was successful. If so, no further action is taken as indicated at step 260. However, if a flame is not present, the tries counter is incremented at step 262 and thereafter tested in step 264 to determine whether four tries at ignition have been made. If four tries have not been made, the program control loops back to the initiate ignition sequence 256 with the now updated value in the tries counter.
On the other hand, if four tries have been made, program control proceeds to the error determination steps wherein the low battery flag is first tested in step 266. If the battery is in fact low, a low battery message is displayed in step 268. On the other hand, if a low battery condition does not exist, the program next tests at 270 to determine whether the fuel supply is depleted. This is done by checking the fuel level variable. If the fuel level is below a predetermined amount, the "Fuel Out" display is issued in step 272. If neither of these error conditions are met, the program does not alter the display.
In any event, when the program determines that a flame is not present, the audible alarm is sounded to allow the user to correct the situation. It will be understood that the routine of FIG. 11 is called by the Master Loop by the light burner routine 210. When the routine of FIG. 11 reaches any one of steps 252, 260, 268, 272 or 270, program control returns to the Master Loop.
Microprocessor 84 can display the fuel level, preferably in 1/8 increments between full and empty. In the alternative, microprocessor 84 has been programmed to compute the fuel level in terms of the time remaining before refueling is necessary. This remaining burning time is calculated arithmetically by determining the numerical value output by potentiometer 56 and by then dividing this value by a number representing the weight of fuel burned per increment of time (e.g., ounces per hour). The value from potentiometer 56 represents the weight of fuel remaining in the canister, since the weight of the canister has already been calibrated out of the equation by adjustment of potentiometer 102. This calculated value can then be displayed in lieu of the fuel level in 1/8 tank increments.
From the foregoing it will be appreciated that the present invention provides an integrated microprocessor controlled circuit for controlling ignition and for monitoring fuel levels, cooking temperatures and cooking times as well as monitoring when the grill has preheated to an appropriate starting temperature. While the invention has been described in connection with its presently preferred embodiments, it will be understood that the invention is capable of modification without departing from the spirit of the invention as set forth in the appended claims. | The electronic grill control employs a microprocessor-based circuit which monitors cooking temperature, cooking time, fuel level and the presence or absence of flame. The fuel level may be displayed alternately as a percentage or fraction of the full tank capacity or in terms of the burning time remaining in the tank. A dual electrode ignition circuit eliminates noise problems in the microprocessor circuitry by establishing the appropriate sparking voltage between the two electrodes instead of between a single electrode and the casting ground. A fuel presence sensor comprising one of the two electrodes measures resistance or conductance of the ionized gases within the flame to provide the microprocessor with an indication that the flame has failed to ignite or has blown out. All information is displayed on an alphanumeric display with audible alarms provided for certain conditions. | 5 |
BACKGROUND OF THE INVENTION
The present invention relates to an embroidery data processing device for reading an image data representing a picture pattern and extracting a shape of the picture pattern from the image data.
Conventionally, in a field of industrial sewing machines, an embroidery data processing device which is provided with a micro-computer and is capable of processing embroidery data having high precision within a relatively short period of time is known. In such an embroidery data processing device, however, when an embroidery data is generated based on an original picture pattern (i.e., a desired image), the picture pattern should be input manually, for example, using a mouse, a digitizer, or the like.
For example, when an embroidery data of a picture pattern of a "face" of a dog as shown in FIG. 1 is created, the following should be considered.
A frame of the "face" has an outer outline L0 and an inner outline L1. Thus, in order to input the shape of the "face" in the embroidery data processing device, the outlines L0 and L1 should be traced accurately. Further, outlines of two "eyes" should also be input by tracing outlines thereof.
It is preferable that, to portions of the "face" drawn as lines rather than areas, a line stitch, such as a running stitch, a zigzag stitch or the like should be assigned. For assigning such a line stitch, as shown in FIG. 2, the frame of the "face" is divided into frame outlines C0, C1, and stitching outlines T0-T5, and these outlines should be input in the embroidery processing device instead of the outlines L0 and L1. In this case, to the frame outlines C0 and C1, a Tatami stitch or the like is assigned in order to fill the area enclosed by the outlines C0 and C1, and to the stitching outlines T0-T5, a zigzag stitch or the like is assigned along paths defined by the outlines T0-T5.
Recently, due to variety of operator tastes, improvement of functions of the sewing machines, and the like, there is a demand for an embroidery data processing device capable of creating an embroidery data for not only one of predetermined embroidery patterns but also a desired pattern which can be used by the personal sewing machines.
For the embroidery data processing device for personal use, it is preferable that the desired pattern can be input easily without necessity of tracing an original picture. For example, it is preferable that the original picture which is drawn by a user with a pen or the like can be converted into an embroidery data for a high-quality embroidery with a simple operation.
For avoiding the manual tracing process as used in the conventional industrial sewing machines, there has been suggested an embroidery data processing device employing image processing algorithms such as edge tracing, and thinning algorithms. With such an embroidery data processing device, a shape of a picture drawn on a sheet of paper can be extracted as an embroidering area automatically. An example of such a device is disclosed in Japanese Patent Provisional Publication HEI 8-44848, and teachings of which are incorporated herein by reference.
In the device in which the original picture pattern should be manually traced to input the data of paths to which line stitch is to be assigned and/or areas to which fill-in stitch is assigned, tracing should be performed very carefully. To trace the original pattern accurately is a troublesome and time consuming work, especially for ordinary users who may not skilled in tracing work. In particular, if the original pattern is relatively large and complicated, a long period of time is necessary to trace, and further, a profound knowledge on creating the embroidery data is required.
As for a device which automatically extracts the shape of the pattern, there is a problem described below. That is, if the original pattern includes two-dimensionally extending areas and linear areas, and such areas are connected (e.g., the "face of a dog" shown in FIG. 1), the thinning process is not applied to such areas, and only the outlines (i.e., the outlines L0 and L1) are extracted. In such a case, a Tatami stitch or satin stitch is assigned to all the extracted areas if the data of the extracted areas is used as it is, and accordingly, the extracted data should be processed. In other words, with the data automatically extracted based on the original pattern as shown in FIG. 1, the two-dimensionally extending areas and the linearly extending areas cannot be distinguished automatically, and accordingly it is impossible to use the Tatami stitch and the zigzag stitch separately depending on the portions of the extracted outlines. Therefore, it is impossible to create the embroidery data for generating a beautiful and high-qualified embroidery if the automatically extracted data is used without being processed by an operator.
SUMMARY OF THE INVENTION
It is therefore an object of the invention to provide an improved embroidery data processing device which is capable of extracting the shape of an original picture pattern, and further, creating an embroidery data with which a beautiful and highly-qualified embroidery can be made.
For the above object, according to one aspect of the invention, there is provided an image data processing device for processing image data representing a predetermined pattern, comprising: an area discriminating system which discriminates two-dimensionally extending areas from linearly extending areas included in the predetermined pattern; and a vector data creating system which creates vector data for respective ones of the two-dimensionally extending areas and the linearly extending areas, the vector data creating system applying different algorithms to image data representing the two-dimensionally extending areas and to image data representing the linearly extending areas.
Since original image data is examined and the two-dimensionally extending areas and the linearly extending areas are discriminated and processed separately, the image data can be processed appropriately. For example, an edge tracing process is applied to the two-dimensionally extending areas, and a thinning process is applied to the linearly extending areas.
According to another aspect of the invention, there is provided a method of processing image data representing an embroidery pattern and creating embroidery data, comprising the steps of: extracting first image data representative of two-dimensionally extending areas from the image data representing the embroidery pattern; extracting second image data representative of linearly extending areas from the image data representing the embroidery pattern; and creating the embroidery data by applying different algorithms to the first image data and to the second image data.
As above, since the areas included in the embroidery pattern are discriminated and different algorithms are applied to the first and second image data, either the first or second image data is processed and an appropriate embroidery data can be created.
Optionally, the image data may be gray scale bit map data of the embroidery pattern, and wherein the method may include a step of converting the gray scale bit map data into binarized bit map data before the different algorithms are applied to the first and second image data.
According to further aspect of the invention, there is provided an embroidery data processing device for processing image data representing an embroidery pattern and creating embroidery data, comprising: a two-dimensional area extracting system which extracts first image data representative of two-dimensionally extending areas from the image data representing the embroidery pattern; a linearly extending area extracting system which extracts second image data representative of linearly extending areas from the image data representing the embroidery pattern; and an embroidery data creating system which creates the embroidery data, the embroidery data creating system applying different algorithms to the first image data and to the second image data for creating the embroidery data.
Since the two-dimensionally extending areas and the linearly extending areas are processed separately, the embroidery data having high precision can be generated with ease.
Optionally, the two-dimensionally extending area extracting system comprises: a distance converter which applies distance conversion to each area included in the image data representing the embroidery pattern to generate distance value data representing a distance value of each pixel; an pixel eliminating system which eliminates the distance value data representing a distance value which is not more than a predetermined distance value; and an inverse distance converter which applies inverse distance conversion to the distance value data that has not been eliminated by the pixel eliminating system.
By applying the distance conversion, the linearity of each area can be represented by distance values of the pixels. Thus, the data representing one of the two-dimensionally extending areas or the linearly extending areas can be eliminated based on the distance values. For example, by eliminating the data representing the pixels having the distance values less than a predetermined value, relatively linear areas can be removed.
Further optionally, the linearly extending area extracting system comprises a first subtracting system which subtracts the image data to which the distance conversion and the inverse distance conversion have been applied from the image data to which the distance conversion and the inverse distance conversion have not been applied to obtain the second image data. With this subtraction, only the linearly extending areas remain.
Furthermore, the two-dimensionally extending area extracting system further comprises a second subtracting system which subtracts the second image data obtained by the first subtracting system from the image data to which the distance conversion and the inverse distance conversion have not been applied to obtain the first image data. Accordingly, the remainder of the image data is extracted with this subtraction.
Optionally or alternatively, the embroidery data creating system applies an edge tracing process to the first image data which is generated by the two-dimensionally extending area extracting system. Thus, the outlines of the two-dimensionally extending areas can be obtained, and accordingly an appropriate type of stitch can be assigned to the two-dimensionally extending areas.
Further optionally or alternatively, the embroidery data creating system applies a thinning process to the second image data which is generated by the linearly extending area extracting system. Therefore, the linearly extending areas can be converted to data representing paths, and accordingly, an appropriate type of stitch can be assigned to the linearly extending areas.
According to still further aspect of the invention, there is provided an embroidery data processing device for processing image data representing an embroidery pattern and creating embroidery data, comprising: means for extracting first image data representative of two-dimensionally extending areas from the image data representing the embroidery pattern; means for extracting second image data representative of linearly extending areas from the image data representing the embroidery pattern; and means for creating the embroidery data by applying different algorithms to the first image data and to the second image data.
According to furthermore aspect of the invention, there is provided a storage medium for storing programs for processing image data representing an embroidery pattern and creating embroidery data, the programs including: a first extracting program that extracts first image data representative of two-dimensionally extending areas from the image data representing the embroidery pattern; a second extracting program that extracts second image data representative of linearly extending areas from the image data representing the embroidery pattern; and a creating program that creates the embroidery data by applying different algorithms to the first image data and to the second image data.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows an example of an embroidery pattern;
FIG. 2 shows outlines which are obtained by tracing the embroidery pattern shown in FIG. 1;
FIG. 3 is a schematic perspective view of an embroidery data processing device embodying the present invention;
FIG. 4 is a block diagram illustrating a control system of the embroidery data processing device;
FIG. 5 is a flowchart illustrating a main process of the embroidery data processing device;
FIG. 6 is a flowchart illustrating a figure separation process called in the main process shown in FIG. 5;
FIGS. 7A and 7B show an embroidery pattern and a chart showing a binarized data corresponding to a part of the embroidery pattern;
FIG. 8 shows a chart illustrating a distance values of each pixel;
FIGS. 9A and 9B show two-dimensionally extending areas and linearly extending areas as extracted, respectively; and
FIG. 10 is an example of embroidery formed in accordance with the embroidery data.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
An embodiment of the present invention will be described with reference to accompanying drawings. It should be noted that FIG. 1 is referred to when the conventional art is described, and the same drawing will also be referred to when the embodiment according to the present invention is described.
Firstly, a personal embroidery sewing machine (not shown) will be described briefly. The embroidery sewing machine is provided with a frame for supporting a cloth on which the embroidery is formed. The frame is located on a sewing machine bed, and movable in X and Y directions which are perpendicular to each other, and are also perpendicular to moving direction of a needle of the sewing machine. By a moving mechanism, the frame is moved in the X and Y directions while sewing is executed, a two-dimensional pattern is embroidered on the cloth.
Generally, the moving mechanism and the needle are controlled to move by a controller which is provided in the sewing machine. Specifically, in accordance with stitch position data indicating X and Y coordinates, the controller controls the movement of the frame and the needle so that the pattern represented by the stitch position data is embroidered.
The sewing machine is further provided with a flash memory reading device, and capable of reading the stitch position data stored in the flash memory. In the embodiment described below, the data to be stored, for example, in the flash memory described above is created. That is, the embroidery data processing device according to an embodiment of the present invention is capable of processing embroidery data representing an embroidery pattern and creating the stitch data for the sewing machine described above.
FIG. 3 shows a schematic perspective view of an embroidery data processing device 100, and FIG. 4 is a block diagram illustrating a control system of the embroidery data processing device 100.
The embroidery data processing device 100 has a main body 1 which includes a personal computer having a CPU (Central Processing Unit) 2, a ROM (Read Only Memory) 3, a RAM (Random Access Memory) 4, a display controller 5, a disk controller 6, and an I/O interface 7. The above listed units are all interconnected through a system bus.
The display controller 5 is connected to a displaying device such as a CRT (Cathode Ray Tube) 8 for displaying embroidering patterns, various messages and the like.
The I/O interface 7 is connected to a keyboard 10 which is used for inputting alphanumeric characters, operation commands and the like. Further, the I/O interface 7 is connected with a card connector 11 to which a card-shaped flash memory 12 is connected. Still further, to the I/O interface 7, an image scanner 9 for capturing an image of an embroidery pattern and outputting image data corresponding to the captured image is connected.
The flash memory 12 is used for storing the embroidery data processed by the embroidery data processing device 100.
The disk controller 6 is connected to a hard disk drive 13 which stores programs to be executed by the CPU 2 for operating embroidery data processing, newly creating embroidery data and the like.
When the embroidery data processing device 100 is turned ON, a program loader stored in the ROM 3 controls the disk controller 6 to load the programs stored in the hard disk drive 13 into the RAM 4. Then the CPU 2 is ready to execute the loaded programs to perform various embroidery data processings.
In the following description, the embroidery data creating operation for creating the embroidery data representing the embroidery pattern of the "face of a dog" shown in FIG. 1 will be described, with reference to a flowchart shown in FIGS. 5 and 6.
At S1, the original embroidery pattern which may be drawn on a sheet of paper or the like is scanned by the image scanner 9. The original pattern is, for example, a picture as shown in FIG. 1. The image scanner 9 is capable of outputting gray scale image data having values of 256 steps (i.e., 0-255) for each pixel. Where the data value 0 represents a white image, and the data value 255 represents a black image. The image data output by the image scanner 9 is image data of raster format bit map. In other words, the image scanner 9 outputs one-byte (i.e., eight-bit) gray scale data for each pixel. The gray scale bit map data output by the image scanner 9 is stored in an original image data storing area (not shown) in the RAM 4.
At S2, the gray scale bit map data is converted into binarized (i.e., two-value) data with use of a comparator. Specifically, the bit map data for each pixel is compared with a predetermined threshold value Th (e.g., Th=127), and each one-byte data is converted into a one-bit data, i.e., the binarized data. If a data value for a pixel is greater than the threshold value Th, a value "1" is set to a new data value for the pixel, and if a data value for a pixel is not greater than the threshold value Th, then a value "0" is set to a new data value for the pixel. With this binarizing process, a black portion of the original pattern is represented by pixels having the value "1", and a white portion of the original pattern is represented by pixels having the value "0". FIG. 7A shows an example of the binarized bit map data representing a portion of the face of the dog indicated in FIG. 7B.
At S3, based on the binarized bit map data, figures (shapes) are extracted, and divided into two-dimensionally extending figures and linearly extending ones, where each figure consists of a set of pixels having a data value of "1" and adjoningly connected. This process will be described in detail with reference to FIG. 6.
At S31, The binarized bit map data is copied into a predetermined address in the RAM 4 as image data A. It should be noted that copying of the original image data is done merely by copying the data values of the original data into a certain area of the RAM 4.
At S32, distance conversion is applied to the image data A. The distance conversion in connection with the binarized bit map data is an operation to determine a distance value, for each pixel, indicating how far each pixel is apart from an edge of the figure. A method of applying the distance conversion is well-known, and an example of which is described in Junichiro Toriwaki, Digital Image Processing for Image Understanding II!, (Tokyo: Shokodo, 1988), and a detailed description will be omitted herein.
If a four-point connected distance or an eight-point connected distance is to be obtained by the distance conversion, the distance conversion can be performed relatively easily by a serial processing through a raster scanning of the pixels of the image data A. FIG. 8 shows the image data A' corresponding to the image data A after the distance conversion of the four-point connecting distance has been applied to the portion of the image data A shown in FIG. 7A.
At step S33, pixels which have the distance value equal to or less than a value Df are removed from the image data A'. The value Df is a parameter referred to when inverse distance conversion is performed. Specifically, the value Df defines an extent of an area of a figure to be restored when the inverse distance conversion is performed. When the value Df has a relatively larger value, figures having larger areas will be restored, and figures having linear areas and/or small areas will not be restored. In other words, setting of the value Df defines a border between wide areas and linear areas. By changing the value Df, the border can be adjusted. The value Df should be determined based on the resolution of the image data and fineness of the original pattern. In this embodiment, the value Df is determined as three (i.e., Df=3). Accordingly, the distance values of the pixels in the image data A' to which the inverse distance conversion has been applied are examined, and the distance values of the pixels equal to or less than 3 are changed to 0 (zero).
At S34, to the image data A', the inverse distance conversion is applied. The inverse distance conversion is an operation of restoring an original image data, and an example of an algorithm for the inverse distance conversion is also described in Digital Image Processing for Image Understanding II!, and a description will be omitted. It should be noted that since the pixels having the distance values equal to or less than 3 have been canceled at S33, figures restored by the inverse distance conversion are a part of the entire pattern, and pixels included in the restored image data have the distance values which are more than three, respectively. In other words, figures which have certain two-dimensional areas are retrieved at this stage. Thus, as the image data A, binarized bit map data representing figures having two-dimensionally extending areas is obtained.
At S35, from the original image data, the image data A is subtracted, and a new image data B is generated. Specifically, data values of corresponding pixels of the original data and the image data A are compared, and if a data value of the image data A is zero, the data value of the original data is stored as the data value of the corresponding pixel of the image data B, and if the data value of the image data A is not zero, zero is stored as the data value of the corresponding pixel of the image data B. Note that the image data B is stored in the RAM 4 at an address which is different from those of the original data and the image data A. Thus, in the above process of S35, the image represented by the image data A is subtracted from the image (the original embroidery pattern) represented by the original image data, and the remainder image data is stored as the image data B. Therefore, the image data B represents a bit map corresponding to the linearly extending portions of the embroidery pattern.
It should be noted, that the image data B includes bit map data corresponding to not only linearly extending areas but also small areas even if they are not linearly extending. The small area patterns include a smaller number of pixels, and accordingly cannot have greater distance values (i.e., a pixel at a central portion of the small area cannot have a great value representing a distance to the edge of the area), and therefore excluded from the image data A representing the larger areas.
At S36, the above-described small areas which are not linearly extending are removed from the image data B. For this purpose, in the areas represented by the image data B, the number of pixels included in each figure of the image data B is calculated. If the number of pixels included in an area is equal to or smaller than a predetermined number N, the distance values of the pixels included in the area are set to zero. Note that the number N is determined based on the resolution of the image data and fineness of the embroidery pattern. In this embodiment, the number N=20.
Alternatively, whether a figure is to be removed may be determined based on not only the number of pixels included in the figure, but also a length of the outline of the figure. In accordance with such a method, a figure which has a relatively long shape (i.e., a linear shape) can be retained in the image data B even if the number of the pixels of the figure is relatively small. An example of such a method of evaluating an oblateness of a figure based on the number of the pixels and the length of the outline is disclosed in Japanese Patent Provisional Publication HEI 7-136357, teaching of which is incorporated herein by reference.
At step S37, from the image represented by the original image data, an image represented by the image data B is subtracted, and a new image data A representing the resultant image is generated. Specifically, data values of corresponding pixels of the original image data and the image data B are compared, and if a data value of the image data B is zero, the data value of the original data is stored, and if the data value of the image data B is not zero, zero is stored, as the data value of the corresponding pixel of new image data A. Thus, the new image data A represents a bit map of the binarized data indicative of two-dimensionally extending figures.
With the figure separation process executed from S31 through S37, the bit map data for the two-dimensionally extending figures are stored as the image data A, and the bit map data for the liner figures are stored as the image data B, separately. Figures represented by the image data A and image data B are shown in FIGS. 9A and 9B, respectively.
After the figure separation process shown in FIG. 6 is finished, control goes to S4 of FIG. 5. At S4, each figure represented by the image data A and the image data B are converted into vector data.
To the figures having two-dimensionally extending areas, a well-known edge tracing process is applied, and an outline consisting of connected pixels is extracted, and then the data representing the extracted edge is converted into vector data. As a method of converting an outline to the vector data, one of the connected pixels (e.g., an upper left pixel) is determined as a starting point, and then a chain of the connected pixels is traced sequentially to sample the coordinates corresponding to the connected pixels representing the outline. For the linear areas in the image data A, the thinning process is applied and then vectorized such that the data representing the linear area is converted into a series of path data. The thinning process is done by sequentially removing pixels form the edge portions of a figure in accordance with a predetermined algorithm until no more pixels can be removed. As a thinning process, Hilditch method is well known, which is described in Digital Image Processing for Image Understanding II!.
The vector data representing partial figures of the embroidery pattern is finally converted into stitch data in a stitch data converting process at S5. In this step, based on the vector data, the stitch data indicating a plurality of stitching points is generated. A process for generating the stitching data is carried out as described below.
With respect to the pattern area surrounded by an outline, a plurality of stitching points (coordinates) for full-filling the area are generated in accordance with the type of embroidery such as the Tatami stitch, the satin stitch, or the like assigned to the area. With respect to an area indicated as a path, a plurality of stitching points located along the path are generated in accordance with the type of embroidery such as the running stitch, the zigzag stitch, or the like assigned to the path. The stitch data including the stitch points as described above is further added with the thread color codes, thread change codes, and the like, and then stored in the flash memory 12 in the form which is readable by the sewing machine. Thus, the figure of the "face of the dog" shown in FIG. 1 can be embroidered by a sewing machine in accordance with the stitch data stored in the flash memory 12.
FIG. 10 shows an example of the embroidery formed by the sewing machine in accordance with the stitch data generated as described above.
According to the embroidery data processing device embodying the present invention, an original pattern drawn on a sheet of paper is scanned by a scanner, and then, the original pattern is divided into two-dimensionally extending areas and linear elongated areas. The two-dimensionally extending areas are converted into the embroidery data having the data of the Tatami stitches, the satin stitches or the like. The linearly extending areas are converted into the embroidery data having the data of line stitches such as the running stitch, the zigzag stitch or the like. Such conversion from the pattern data into the embroidery data can be done automatically. Therefore, the stitch data for a high-qualified, and beautiful embroidery can be generated easily.
In the above-described embodiment, the original pattern is captured as gray scale image data. Alternatively, the image data can be captured as color image data, and in such a case, binarized data can be created using the data of a desired one of the plurality of colors. Further alternatively, instead of scanning the original with use of the scanner, the data read by a video camera or the like can be used. Furthermore, The original image can be input to the embroidery data processing device through a floppy disk or the like, or a data communication line (wired or wireless).
Further, the format of the stitch data is not limited to the format described above, but can be a so-called block format or the like. Furthermore, the stitch data can be generated directly based on the bit map, without generating vector data.
In the above-described embodiment, as a recording medium for storing the sewing data, the flash memory is used. However, it is not limited to this example, and alternative medium, such as floppy disk can also be used. Further, instead of using a recording medium, a communication system (either wired or wireless) can also be used for transmitting the stitch data from the embroidery data processing device to the sewing machine.
Still further, in the embodiment, the personal computer is used as the embroidery data processing device. However, it may be possible to provide an integral device using a microcomputer exclusively for processing the embroidering data. Alternatively or optionally, the embroidery data processing device according to the invention can be incorporated into a sewing machine.
The present disclosure relates to the subject matter contained in Japanese Patent Application No. HEI 8-275955, filed on Oct. 18, 1996, which is expressly incorporated herein by reference in its entirety. | Disclosed is an embroidery data processing device. First image data representative of two-dimensionally extending areas, and second image data representative of linearly extending areas are extracted, and then processed in accordance with different algorithms. To the two-dimensionally extending areas, an edge tracing process is applied to obtain outlines thereof, and to the linearly extending areas, a thinning process is applied to obtain paths defined thereby. Different types of stitches are assigned to the extracted areas. | 3 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of U.S. application Ser. No. 11/293,437 filed Dec. 2, 2005, now abandoned which claims the benefit of the U.S. Provisional Application No. 60/633,411, filed Dec. 3, 2004.
BACKGROUND OF THE INVENTION
This invention relates in general to bookmarks. More particularly, the invention pertains to bookmarks that have been adapted to provide multiple purposes beyond serving as a mark for a page in a book, magazine, journal or the like.
Bookmarks primarily serve the singular purpose of marking the page or pages for a person reading a book, magazine, journal or the like. However, the bookmark may take the form of various shapes and sizes, or contain varying artwork or words for a user's enjoyment. Primarily bookmarks have a first portion that is inserted between pages of a book, and a second portion connected to the first portion that extends beyond a periphery of the pages of the book. With such a configuration, when a person stops reading a book, the reader places the bookmark in a desired position on the page being read and closes the book. Having the second portion protruding beyond the periphery of the book enables the reader to readily locate the page on which the person stopped reading.
Ben-Dor et al., in U.S. Pat. No. 6,722,309, discloses a bookmark that may serve another purpose other than simply marking a page in a book. The bookmark has an upper hook-like section that rides over the binding of a book, and acts as an “attention-attracting” item, such as pencil sharpener, photograph or advertising piece, which may be attached to the hook-like section. The '309 patent also mentions that the bookmark itself may be formed of a suitable candy substance. Accordingly, the use of the bookmark as a candy substance raises sanitary issues.
BRIEF DESCRIPTION OF THE INVENTION
The present invention is for a bookmark has a limited first lifecycle for use as a bookmark, and when a book is completed the bookmark is retained as a keepsake containing information relative to a reader and/or a book having been read by a user. To that end, the present invention is for a bookmark having a compartment for storing an article for use by a reader, the article being placed in the pouch by the manufacturer of the bookmark. The bookmark preferably comprises a lower pouch having a sealed top end and a sealed bottom end. A tab is affixed to the top end of the pouch so that a portion of the pouch may be inserted between pages of a book, wherein at least a portion of the tab protrudes from a periphery of a book, or pages of a book, to serve as a book mark. The compartment of the pouch holds the article, and the compartment can be opened to access and retrieve the article. In an embodiment the bottom end of the pouch is detachable from a remaining portion to open the pouch and compartment. In addition, the tab or pouch may contain data entry for inputting data relative to the book and person reading the book. The tab may also have fanciful indicia that may be relevant to the book, the article in the pouch or relevant to a reader's likenesses.
The invention is ideally suited for children, but not limited to use by children. The invention provides a reward for a child reader upon completion of a book. Once a child finishes reading a book a bottom end of the pouch is detached from a remaining portion of the pouch to retrieve the article. In addition, the child and/or parent of the child, may record on the bookmark the name of the child, the title of the book and the date the child completed reading the book. The bookmark of the present invention also provides a sanitary delivery system in the case the article is an edible insert used with the bookmark.
BRIEF DESCRIPTION OF THE DRAWINGS
A more particular description of the invention briefly described above will be rendered by reference to specific embodiments thereof that are illustrated in the appended drawings. Understanding that these drawings depict only typical embodiments of the invention and are not therefore to be considered to be limiting of its scope, the invention will be described and explained with additional specificity and detail through the use of the accompanying drawings.
FIG. 1 is a front elevational view of an embodiment of the bookmark according to the present invention.
FIG. 2 is a rear elevational view of an embodiment of the bookmark according to the present invention, showing horizontally disposed data fields for entry of historical data relative to the reader and/or book.
FIG. 3 is a perspective view of a book in which the bookmark according to the present invention is placed.
FIG. 4 is a rear elevational view of an embodiment of the bookmark according to the present invention having vertically disposed data entry fields for recording historical data relative to a reader and/or the book.
FIG. 5 is a front elevational view of an embodiment of the bookmark according to the present invention having an insert being retrieved from the bookmark.
FIG. 6 is a front elevational view of an embodiment of the bookmark according to the present invention with an enlarged oval backdrop as part of the tab.
FIG. 7 is a front elevational view of an embodiment of the bookmark according to the present invention with an enlarged rectangular backdrop as part of the tab.
DETAILED DESCRIPTION OF THE INVENTION
An embodiment of the invention is illustrated in FIGS. 1 , 2 and 3 . The bookmark 10 shown in FIG. 1 includes an upper section or tab 11 and a lower pouch 12 for holding an article 13 that is useable for a reader. At least a portion of the pouch 12 is inserted between pages 18 of a book 17 . As shown in FIG. 3 at least a portion of the tab 11 extends or protrudes beyond a periphery defined by the outer edges of pages 18 or the outer edge 17 A of the book 17 to mark the page or location in a book where a person is reading. The article 13 may take the form of any item that can fit within the compartment 19 . For example, the article 13 may include edible items such as gum sticks, taffy, pressed fruit, hard candy or the like or paper items providing game pieces, coupons, promotional pieces, etc. The article 13 is preferably thin and not bulky such that the book cannot be closed when not in use.
With respect to FIGS. 1 and 2 , the tab 11 may have an indicia 23 such as fanciful character or design disposed on a first side 11 A of the tab 11 , and data entry fields 24 disposed on a second side 11 B of the tab 11 . Alternatively, a character or design may be printed on a separate piece of material, which is adhered to the tab 11 . In another embodiment, the tab 11 of the bookmark 10 may include a logo of a manufacturer and/or distributor of the article 13 within the compartment; or, the indicia 23 may be a character or design that has some relevance to the readable item 17 or to the reader.
The data entry fields 24 may be printed directly on the tab 11 ( FIG. 2 ) or the pouch 12 ( FIG. 4 ). Alternatively the data entry fields may be printed on a medium that can be adhered to the tab 11 or pouch 12 . The data entry fields 24 provide space to record information about the reader and/or the book, such as name of the reader, the title of the book, and the date the reader completed reading the book. After the reader completes the book, the above referenced information can be recorded on the available space and bookmark 10 or sections 11 and 12 containing the information and stored as a keepsake. After the book is read, the article is removed from the pouch 12 . The pouch 12 and tab 11 , at this stage, no longer serve the function of a bookmark but are intended to be retained as a keepsake as explained in more detail below.
In an embodiment as mentioned above, the pouch 12 may be formed from available materials such as paper, cellophane, plastics, aluminum used in packaging and is thin enough to tear. Typically, a single sheet of material is folded and sealed at a top end 12 A and bottom end 12 B, and along a side edge 12 C of the pouch 12 forming the compartment 19 therein. In any of the embodiments shown in FIGS. 1 through 7 , the tab 11 may be composed of a material that is different than the material making up the pouch 12 . For example, tab 11 may be a cardstock paper, cardboard, plastic or any material to which the lower section 12 can be attached.
In any of the embodiments shown in FIGS. 1 through 7 , the tab 11 and pouch 12 may be composed of the same materials whereby a seal 25 is formed between the tab 11 and pouch 12 . By way of example shrink wrapping, vacuum sealing or heat sealing technology may be used to form the seal 25 between the tab 11 and pouch 12 . Heat applied to the tab 11 , or an area between the tab 11 and pouch 12 forms the seal 25 . The indicia 23 may be printed on the tab 11 , or adhered to the tab 11 as a separate part. In the embodiments shown in FIGS. 6 and 7 , the tab 11 includes an enlarged background for printing or adding artwork.
With respect to FIG. 5 , the pouch 12 includes a means for opening the pouch 12 or compartment 19 to retrieve the article 13 . In an embodiment shown in FIG. 5 , a bottom end 12 B of the pouch 12 is detachable from a remaining portion of the pouch 12 . As shown in FIGS. 1 , 2 and 4 , the pouch 12 includes a perforation 20 disposed on the pouch 12 distal the tab 11 forming the detachable bottom end 12 B. The means for opening the pouch 12 or compartment 19 is not limited to a perforation, but may include other methods or devices that are known to those skilled in the art that form a weakened area along a material to enable one to cleanly open an enclosure, such as a small gap formed in the pouch 12 to initiate a tear.
The invention is ideally suited for children, but not limited to use by children, wherein the bookmark 10 provides a reward for a child reader upon completion of a book 17 . As shown in FIG. 4 , once a child finishes reading a book the lower section 12 is separated from upper section 11 and/or opened to retrieve the article 13 , which may be an edible insert. The lower section 12 and upper section 11 may be disposed of, if the bookmark is of a disposable nature as described above. In the embodiments shown in FIGS. 4 and 7 , upper section 11 or lower section 12 have space available for recording the child's accomplishment. For example, the child and/or parent of the child, may record the name of the child, the title of the book and the date the child completed reading the book. The tab 11 and remaining portion of the pouch 12 are retained as a keepsake and no longer useable as a bookmark, thereby provided a historical keepsake having information relative to the reader and/or book.
While the preferred embodiments of the present invention have been shown and described herein, it will be obvious that such embodiments are provided by way of example only and not of limitation. Numerous variations, changes and substitutions will occur to those skilled in the art without departing from the teaching of the present invention. Accordingly, it is intended that the invention be interpreted within the full spirit and scope of the appended claims. | A bookmark has a compartment for storing an article for use by a reader. The bookmark preferably comprises a pouch that is capable of being placed between pages of a book, and a tab that protrudes from a periphery of a book or pages of a book. The pouch holds an article in the compartment, which can be opened to access and retrieve the article. In addition, the tab or pouch may contain data entry fields for inputting data relative to the book and person reading the book. Indicia may also be disposed on a surface of the tab. | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority to and the benefit of U.S. Ser. No. 62/092,488 which was filed on Dec. 16, 2014 and which is incorporated herein by reference in its entirety.
BACKGROUND
To hide brackets and rollers of window shades from plain sight, contractors may install the brackets and rollers into a ceiling recess, removing them from plain sight. Such recesses typically have an opening through which a contractor may install and access a roller shade. The opening is typically covered such that the material of the cover abuts a material covering the ceiling base and a slit is left in the middle of the material covering the opening. The slit may allow a shade to be deployed into the room use to cover a window and allow the shade to be retracted from the room for storage. However, these current systems for storing and deploying roller shades typically create a visually unpleasing juncture at the interface of the material covering the ceiling base and the material covering the opening of the recess.
SUMMARY
An exemplary embodiment relates a window shade storage and deployment system. The window shade storage and deployment system includes a recess formed in a ceiling and configured to house a window shade movable between a retracted position and an extended position. The window shade storage and deployment system further includes an access panel removably attached to a surface of the recess such that a visible surface of the access panel occupies substantially the same plane as a visible surface of the ceiling surrounding the recess. A gap is provided between an edge of the access panel and the ceiling. The gap is configured to enable the window shade to extend through the gap from the recess to the area below the visible surface of the ceiling when the window shade is in the extended position. The visible surface of the access panel and the visible surface of the ceiling include the same or a similar material such that the visible surface of the access panel and the visible surface of the ceiling are visibly substantially identical.
Another exemplary embodiment relates to a shade storage and deployment system. The shade storage and deployment system includes a recess formed in a ceiling and configured to house a first shade and a second shade. The first and second shades are movable between a retracted position and an extended position. The shade storage and deployment system further includes an access panel removably attached to a surface of the recess such that a visible surface of the access panel occupies substantially the same plane as a visible surface of the ceiling surrounding the recess. A first gap is provided between a first edge of the access panel and a first edge of the ceiling and a second gap is provided between a second edge of the access panel and a second edge of the ceiling. The first gap is configured to enable the shade to extend through the first gap from the recess to the area below the visible surface of the ceiling when the first shade is in the extended position. The second gap is configured to enable the shade to extend through the second gap from the recess to the area below the visible surface of the ceiling when the second shade is in the extended position. The visible surface of the access panel and the visible surface of the ceiling include the same or a similar material such that the visible surface of the access panel and the visible surface of the ceiling are visibly substantially identical.
Another exemplary embodiment relates to a shade storage and deployment assembly. The shade storage and deployment assembly includes a housing configured to be installed in a recess of a ceiling. The housing includes a visible surface of the housing configured to occupy substantially the same plane as a visible surface of the ceiling surrounding the housing when the housing is installed in the recess of the ceiling. The housing further includes a window shade movable between a retracted position and an extended position. The housing further includes an access panel removably attached to a surface of the housing such that a visible surface of the access panel occupies substantially the same plane as the visible surface of the housing. A gap is provided between an edge of the access panel and the visible surface of the housing. The gap is configured to enable the window shade to extend through the gap from the housing to the area below the visible surface of the ceiling when the shade is in the extended position. The visible surface of the access panel and the visible surface of the housing include the same or a similar material as the visible surface of the ceiling such that the visible surface of the access panel, the visible surface of the housing, and the visible surface of the ceiling are visibly substantially identical.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A-1C are perspective views of an example shade storage and deployment system according to an implementation described herein;
FIG. 1D is a diagram of the example shade storage and deployment system of FIGS. 1A-1C including more than one shade according to an implementation described herein;
FIG. 2 is a diagram of an example shade storage and deployment system including one shade according to an implementation described herein;
FIG. 3 is a diagram of an example shade storage and deployment system that includes a different spacer component than that shown in FIG. 1D and according to an implementation described herein;
FIG. 4 is a diagram of an example shade storage and deployment system that includes a spacer component in a different position than that shown in FIG. 1D and according to an implementation described herein;
FIGS. 5A-5D are diagrams of example attachment mechanisms and spacer components of an example shade storage and deployment system according to an implementation described herein;
FIGS. 6A-6C are bottom elevational views of the example shade storage and deployment system of FIGS. 1A-1C ;
FIG. 7 is a bottom elevational view of an example shade storage and deployment system according to an implementation described herein;
FIG. 8 is a diagram of an example shade storage and deployment system of FIGS. 1A-D that includes a mount component in a different position than that shown in FIG. 1D and according to an implementation described herein;
FIGS. 9A-C are bottom elevational views of an example shade storage and deployment system according to an implementation described herein; and
FIGS. 10A-C are diagrams of example shade storage and deployment systems that include different spacer components than that shown in FIGS. 6A-C and according to an implementation described herein.
FIG. 11 is a bottom perspective view of an example assembly of a shade storage and deployment system.
DETAILED DESCRIPTION
FIGS. 1A-10C are attached thereto and incorporated herein by this reference. The following detailed description refers to the accompanying FIGS. 1A-8 . The same reference numbers in different figures may identify the same or similar elements.
The systems, methods, apparatuses, devices, technologies, and/or techniques (hereinafter referred to as the “system”), described herein, may enable a visually pleasing juncture to be created between a material covering a recess, in which mounts and shades are installed, and a material covering a ceiling base.
The system may include one or more mount that is configured to be secured to a member of a structure (e.g., joist, beam, ceiling beam, ceiling joist, roof truss, wall stud, top, bottom, or side wall of a recess, floor joist, any other joist, beam, or stud etc.). The one or more mount may be configured to support one or more tube (e.g., a roller shade tube). The one or more tube may be rotatably attached to the mount and the one or more tube may include one or more shade. The one or more tube and/or mount may be configured to be in wired or wireless communication with a control mechanism to enable rotation of the tube. The one or more shade and the one or more tube may be configured such that a free end of the shade is moved away from and/or towards the one or more tube during rotation of the tube and/or shade.
Additionally, or alternatively, the system may include one or more attachment mechanism configured to be attached to a member of a structure (e.g., joist, beam, ceiling beam, ceiling joist, roof truss, wall stud, top, bottom, or side wall of a recess, floor joist, any other joist, beam, or stud etc.). The one or more attachment mechanism may include one or more fastener that is configured to enable another component, such as a spacer, to be removably attachment to the attachment mechanism.
The system may, also or alternatively, include the spacer that enables one or more gap to be created between a ceiling covering and the spacer. The one or more gap may be configured to enable the one or more shade to be deployed and/or retracted through the one or more gap. The spacer may include a corresponding fastener that is configured to enable the spacer to be removeably attached to the fastener of the attachment mechanism. The fastener and/or corresponding fastener may enable the spacer to move laterally and/or vertically within the opening. The spacer may also, or alternatively, include a spacer covering, which may include the same and/or visually similar material to the material of the ceiling covering. Additionally, or alternatively, the spacer may include a deflector that is configured to deflect the shade through one or more gap between the spacer and the ceiling covering. The spacer may include electrical, electronic, or other components (e.g., light source, camera, speaker, microphone, smoke detector, etc.). The one or more gap may prevent the formation of a visually unpleasing juncture. Additionally, or alternatively, the spacer may be oriented such that only the one or more gap used for the retraction and deployment of the one or more shade are created.
The system is described in the context of storing and/or deploying one or more shade from a ceiling. However, in other implementations, the system need not be so limited. For example, the system may be configured to store and/or deploy one or more shade in and/or from any portion of a structure (e.g., floor, wall, window frame, window ledge, counter, outdoor structures, etc.).
Additionally or alternatively, the system is described in the context of storing and/or deploying one or more roller shade. However, in other implementations, the system need not be so limited. For example, the system may also, or alternatively, be configured to store and deploy one or more screen, canvas, and/or other material for a variety of purposes (e.g., temporary flexible barriers, temporary screens, display art work, etc.). Additionally, or alternatively, the system may be configured to enable the storage and/or deployment of other types of shades (e.g., accordion, honeycomb shades, etc.).
FIG. 1A-1C are perspective views of an example shade storage and deployment system according to an implementation described herein. As described in further detail below, the system may include a spacer that is configured to enable the creation of one or more gap between the spacer and a material covering the ceiling base. The one or more gap may allow one (e.g., FIG. 1B ) or more (e.g., FIG. 1C ) shade to be retracted and/or deployed for use.
FIG. 1D is a diagram of an example shade storage and deployment system 100 (hereinafter, “system 100 ”) of FIGS. 1A-1C including more than one shade according to an implementation described herein. As shown in FIG. 1D , system 100 may include one or more mount 101 (hereinafter, “mount 100 ”), one or more rotatable tube 102 (hereinafter, “tube 102 ”), a spacer 110 , and one or more attachment mechanism 120 (hereinafter, “attachment mechanism 120 ”). The number of components, illustrated in FIG. 1D (and/or FIGS. 1A-8 ), is provided for explanatory purposes only and is not intended to be so limited. There may be additional components, fewer components, different components, or differently arranged components than illustrated in FIG. 1D . Also, in some implementations, one or more of the components of system 100 may perform one or more functions described as being performed by another one or more of the components of system 100 .
Mount 101 may be formed by a material of sufficient rigidity and strength to support the weight of tube 102 , shade 103 and/or any static and/or dynamic loads (e.g., forces, torques, tensions, compressions, etc.) imparted on mount 101 by tube 102 , shade 103 , by one or more of components 102 - 124 and/or any additional components (e.g., control mechanism described below). Mount 101 may, for example, be made of metal, plastic, Teflon®, acrylic, urethane, wood, fiberglass, composite, etc., or some combination thereof. The strength and/or rigidity of the material may enable mount 101 to maintain a basic shape when being used and/or to enable various components to be attached to mount 101 and to be used.
Tube 102 may be formed by a material of sufficient rigidity and strength to support the weight of shade 103 and/or any static and/or dynamic loads (e.g., forces, torques, tensions, compressions, etc.) imparted on tube 102 by mount 101 , shade 103 , by one or more of components 102 - 124 , and/or any additional components (e.g., control mechanism). Tube 102 may, for example, be made of metal, plastic, Teflon®, acrylic, urethane, wood, fiberglass, composite, etc. or some combination thereof. The strength and/or rigidity of the material may enable tube 102 to maintain a basic shape when being used, attached to mount 101 and/or any other component, and/or to enable various components to be attached to tube 102 and to be used.
The figures and description herein identify mount 101 as being disk-shaped and/or tube 102 as being generally circular in shape for explanatory purposes. Additionally, or alternatively, in other implementations, the shape need not be so limited. For example, mount 101 and/or tube 102 may be of any shape, such as circular, elliptical, triangular, square, pentagular, hexangular, octangular, etc.
Spacer 110 may include a spacer covering 111 , one or more deflector 112 (hereinafter, “deflector 112 ”), and a corresponding fastener 113 (described in further detail below). Spacer covering 111 may be formed by a material of sufficient rigidity and strength to support the weight of deflector 112 , corresponding fastener 113 , and/or any other component of spacer 110 , and/or any static and/or dynamic loads (e.g., forces, torques, tensions, compressions, etc.) imparted on spacer covering 111 by deflector 112 , corresponding fastener 113 , and/or by one or more of components 102 - 124 (and/or any additional components). Spacer covering 111 may, for example, be made of plaster, metal, plastic, Teflon, acrylic, urethane, wood, fiberglass, composite, etc. or some combination thereof. Spacer covering 111 may be made of a material that is the same as the material of horizontal covering 105 and/or vertical covering 106 (described in further detail below) (e.g., sheet rock, plaster, title, wood, metal, ceramic, etc.) or is made of a material that appears visually similar to the material of horizontal covering 105 and/or vertical covering 106 (e.g., medium density fiber (“MDF”), other fiberboard, etc.). The strength and/or rigidity of the material may enable spacer covering 111 to maintain a basic shape when being used, when being attached to and/or while attached to deflector 112 and/or any other component, and/or to enable various components to be attached to spacer covering 111 and to be used.
The figures and description herein identify spacer 110 and/or spacer covering 111 as being generally rectangular shape for explanatory purposes. Additionally, or alternatively, in other implementations, the shape need not be so limited. For example, spacer 110 and/or spacer covering 111 may be of any shape, such as circular, elliptical, triangular, square, pentagular, hexangular, octangular, etc. Additionally, or alternatively, spacer 110 and/or spacer covering 111 may include a flat shape, a convex shape, concave shape, or combination thereof such that spacer covering 111 may match the contour of horizontal covering 105 and/or vertical covering 106 .
Deflector 112 may be formed by a material of sufficient rigidity and strength to support the weight of spacer covering 111 , corresponding fastener 113 , and/or any other components of spacer 110 , and/or any static and/or dynamic loads (e.g., forces, torques, tensions, compressions, etc.) imparted on deflector 112 by spacer covering 111 , corresponding fastener 113 , and/or by one or more of components 102 - 124 (and/or any additional components). Deflector 112 may, for example, be made of metal, plastic, Teflon®, acrylic, urethane, wood, fiberglass, composite, plaster, sheet rock, etc., or some combination thereof. The strength and/or rigidity of the material may enable deflector 112 to maintain a basic shape when being used, when being attached to and/or while attached to spacer covering 111 and/or corresponding fastener 113 , and/or any other component, and/or to enable various components to be attached to deflector 112 and to be used.
Additionally, or alternatively, deflector 112 may be configured to deflect a free end of shade 103 through gaps 107 and/or 108 (described in further detail below). For example, deflector 112 may include any shape that enables smooth or continuous deflection of shade 103 through gaps 107 and 108 , e.g., such as a curved shape (as shown in FIGS. 1D-5 and 8 ), to enable the deflection of shade 103 while minimizing the risk of tearing and/or otherwise damaging shade 103 . The shape of deflector 112 is not intended to be so limited.
The number of components of spacer 110 , illustrated in the figures, is provided for explanatory purposes only and is not intended to be so limited. There may be additional components, fewer components, different components, or differently arranged components than illustrated in the figures. Also, in some implementations, one or more of the components of spacer 110 may perform one or more functions described as being performed by another one or more of the components of spacer 110 . For example, the figures and description herein identify spacer 110 as including spacer covering 111 and deflector 112 as separate components, for explanatory purposes. Additionally, or alternatively, in other implementations, spacer 110 need not be so limited. In a non-limiting implementation, spacer covering 110 and deflector 112 may be formed as one component that includes one or more materials and/or one or more shape.
Attachment mechanism 120 may include one or more support 124 (hereinafter, “support 124 ”), one or more insert 122 (hereinafter, “insert 122 ”), and one or more fastener 121 (hereinafter, “fastener 121 ”). Support 124 may be formed by a material of sufficient rigidity and strength to support insert 122 , fastener 121 (described in further detail below), spacer 110 , and/or any other components of attachment mechanism 120 and/or spacer 110 , and/or any static and/or dynamic loads (e.g., forces, torques, tensions, compressions, etc.) imparted on support 124 by insert 122 , fastener 121 , spacer 110 , and/or by one or more of components 102 - 124 (and/or any additional components). Support 124 may, for example, be made of metal, plastic, Teflon®, acrylic, urethane, wood, fiberglass, composite, plaster, sheet rock, etc., or some combination thereof. The strength and/or rigidity of the material may enable support 124 to maintain a basic shape when being used, when being attached to and/or while attached to a structural support (e.g., beam, pillar, frame, wall, floor, etc.), insert 122 , fastener 121 , and/or any other component, and/or to enable various components to be attached to support 124 and to be used.
Insert 122 may be formed by a material of sufficient rigidity and strength to support fastener 121 , corresponding fastener 113 , spacer 110 , and/or any other components of attachment mechanism 120 and/or spacer 110 , and/or any static and/or dynamic loads (e.g., forces, torques, tensions, compressions, etc.) imparted on insert 122 by support 124 , fastener 121 , corresponding fastener 113 , spacer 110 , and/or by one or more of components 102 - 124 (and/or any additional components). Insert 122 may, for example, be made of metal, plastic, Teflon®, acrylic, urethane, wood, fiberglass, composite, plaster, sheet rock, foam, etc., or some combination thereof. The strength and/or rigidity of the material may enable insert 122 to maintain a basic shape when being used, when being attached to and/or while attached to support 124 , fastener 121 , and/or any other component, and/or to enable various components to be attached to insert 122 and to be used.
The figures and description herein identify support 124 and insert 122 as being generally rectangular shape for explanatory purposes. Additionally, or alternatively, in other implementations, the shape need not be so limited. For example, support 124 and/or insert 122 may be of any shape, such as circular, elliptical, triangular, square, pentagular, hexangular, octangular, etc. Additionally, or alternatively, while FIGS. 1D-5A illustrate the attachment mechanism as including five inserts (e.g., FIG. 5A ), in other implementations, the attachment mechanism need not be so limited. For example, in a non-limiting implementation, the attachment mechanism may include more or less than five inserts (e.g., as shown in FIG. 5B-5C ) or may not include any insert (e.g., as shown in FIG. 5D ).
As shown in FIG. 1D , system 100 may be configured to be installed into recess 130 , which may be formed, for example, within a ceiling, wall, floor, or other structural element. Mount 101 may be configured to be temporarily and/or permanently secured to a member of a structure (e.g., joist, beam, ceiling beam, ceiling joist, roof truss, wall stud, top, bottom, or side wall of a recess, floor joist, any other joist, beam, or stud etc.) and/or any other portion of a structure sufficient to support the weight and/or forces of mount 101 , tube 102 , and/or any additional component. For example, mount 101 may include one or more aperture that is configured to receive a screw and/or other appropriate fastening means. Mount 101 may be configured to support tube 102 and enable tube 102 to be rotatably attached to mount 101 . For example, system 100 may include two mounts 101 per tube, i.e., one mount for each end of tube 102 . Additionally, or alternatively, mount 101 may have one or more opening (not shown) that is configured to receive one end of (or a portion of one end of) tube 102 , and/or tube 102 may interlock with the one or more opening. Additionally, or alternatively, the one or more opening may include a bearing that is configured to allow tube 102 to rotate freely about tube rotational axis 102 a , minimizing friction and wear.
In other implementations, mount 101 need not be so limited. Mount 101 may be configured to enable tube 102 to rotatably attach to mount 101 by any suitable means generally known in the art. Additionally, or alternatively, mount 101 may be configured such that one mount is sufficient to support tube 102 and allow tube 102 to rotatably attach to mount 101 . Additionally, or alternatively, mount 101 may include a multiple mounting mechanism such that one mount may be configured to support two or more tubes and enable the two or more tubes to be rotatably attached to mount 101 . Additionally or alternatively, the orientation of mount 101 shown in FIG. 1D is not intended to be limiting. FIG. 8 a diagram of an example shade storage and deployment system of FIGS. 1A-D that includes a mount component in a different position that shown in FIG. 1D and according to an implementation described herein. Mount 101 may be configured to be securely attached to a structural member in any orientation that enables mount 101 to support tube 102 and/or shade 103 (e.g., as shown in FIG. 8 ).
Tube 102 may be configured to be removably and rotatably attached to mount 101 , such that tube 102 may rotate about tube rotational axis 102 a . For example, tube 102 may include a mechanism (e.g., key, pin, groove, slot, tab, etc.) that may interlock with a bearing of mount 101 . Additionally, or alternatively, tube 102 may itself include a pivotable mechanism configured to enable tube 102 to rotate about 102 a . In other implementations, tube 102 need not be so limited. Tube 102 may be configured to enable tube 102 to rotate by any suitable means generally known in the art.
Mount 101 and/or tube 102 may be configured to connect to a control mechanism (e.g., motor, servo, air compressor, hydraulic, pneumatic, and/or some other mechanical control system) that is configured to provide a force (e.g., torque on a pin or bearing) to mount 101 and/or tube 102 to cause at least tube 102 to rotate. The control mechanism may be configured to be in wired and/or wireless communication with a user device (e.g., input device, keypad, PDA, phone, laptop, computer, remote control, etc.), sensor (e.g., motion, temperature, pressure, position, etc.), and/or other device (e.g., timer, measurement device, light switch, door, window, television, etc.). The user device, sensor, and/or other device may be configured to send a signal to the control mechanism to automatically rotate (e.g., counter-clockwise, clockwise) tube 102 about tube rotational axis 102 a and/or at least a portion of mount 101 .
One or more shade 103 (hereinafter, “shade 103 ”) may be disposed on and/or wound around tube 102 by any known technique in the art, such that rotation of tube 102 may enable a free end of shade 103 to move away from and/or towards tube 102 , and/or to be deployed and/or retracted through gaps 107 and/or 108 . Shade 103 may be made of any material known in the art of suitable properties (e.g., strength, density, transparency, opaqueness, etc.) and may also, or alternatively, be made of a pliable and/or flexible material that is suitable to be controlled (e.g., bent, conformed, curved, deformed, etc.) upon contact with spacer 110 , such that shade 103 may conform to a same or similar shape of spacer 110 when brought into contact with spacer 110 (“shaped controlled”) (as further described below). FIG. 1D and the description herein identify system 100 as including two tubes 102 and two shades 103 . Additionally, or alternatively, in other implementations, the number of tubes and shades need not be so limited. For example, FIG. 2 is a diagram of an example shade storage and deployment system 200 , which may include only one tube 202 and/or shade 203 .
Returning to FIG. 1D , attachment mechanism 120 may be configured to be temporarily and/or permanently secured to a member of a structure (e.g., joist, beam, ceiling beam, ceiling joist, roof truss, wall stud, top, bottom, or side wall of a recess, floor joist, any other joist, beam, or stud etc.) and/or any other portion of a structure sufficient to support the weight of attachment mechanism 120 , spacer 110 , and/or any additional component. Attachment mechanism 120 may include support 124 , which may be temporarily or permanently secured (e.g., via screw, nail, glued, Velcro®, epoxy, etc.) to a member of a structure. Attachment mechanism 120 may, also or alternatively, include fastener 121 , which may be directly attached to support 124 (e.g., via threaded engagement, etc.) (as shown in FIG. 5D ). Additionally, or alternatively, fastener 121 may be attached to insert 122 (e.g., wooden insert, polymer insert, metal insert, nuts, bolts, etc.) and insert 122 may be attached to support 124 (e.g., via screw, nail, glued, Velcro, epoxy, etc.). Insert 122 may be configured to provide additional support and/or rigidity to fastener 121 . Additionally or alternatively, fastener 121 may be configured to be adjustable in length by any normal methods known in the art (e.g., via adjustment of threaded engagement, telescopic adjustment mechanism, etc.). The number of inserts 122 attached to fastener 121 may depend on, for example, the length of fastener 121 .
Spacer 110 may include corresponding fastener 113 , which may be configured to enable spacer 110 to be removably attached to fastener 121 . Fastener 121 and corresponding fastener 113 may include, for example, attracting magnets with magnetic force that is strong enough to overcome gravitational force and securely attach spacer 110 to fastener 122 without spacer 110 falling, yet weak enough to enable removal of spacer 110 . In other implementations, the type of fastener 121 and corresponding fastener 113 need not be so limited. For example, fastener 121 and corresponding fastener 113 may include any fastening mechanism sufficient to secure spacer 110 to fastener 121 (e.g., key and slot, button, male-female connection, groove and tongue, tab and slot, Velcro®, etc.).
The shapes and sizes of fastener 121 and corresponding fastener 113 shown in the figures and described herein are not intended to be limiting. Additionally or alternatively, in other implementations, fastener 121 and corresponding fastener 113 may be of any shape, dimensions, and/or size suitable to enable removable attachment of spacer 110 and attachment mechanism 120 . For example, the width of corresponding fastener 113 and/or fastener 121 may be as wide as (or nearly as wide as) spacer 110 or a portion of spacer 110 to enable further lateral movement of spacer 110 within a partial opening of recess 130 .
As shown in FIG. 1D , an opening of recess 130 may be partially covered by ceiling base 104 (e.g., joist, beam, truss, etc.), leaving a partial opening of recess 130 . Additionally, or alternatively, ceiling base 104 may include horizontal covering 105 and vertical covering 106 (e.g., made of plaster, wood, sheet rock, ceramic, metal, or a combination thereof, etc.) to effectively prohibit ceiling base 104 from being visual in plain view. The number, shape, size, and/or orientation of ceiling coverings 105 and/or 106 shown in the figures and described herein are not intended to be limited. Additionally, or alternatively, ceiling coverings may include any number, shape, size, and/or orientation necessary to effectively prohibit the ceiling base from being visual in plain view.
Spacer 110 may be oriented into the partial opening of recess 130 such that two gaps 107 and 108 exist between spacer 110 and vertical covering 106 (and/or horizontal cover 106 ). Gaps 107 and 108 may prevent the abutment of spacer 110 with vertical covering 106 and/or horizontal covering 105 , and effectively eliminate a visually unpleasing juncture. This may increase the aesthetic value of the structure, and/or the monetary value of the structure. Additionally, or alternatively, spacer 110 may be oriented to allow one or more shade 103 to be deployed and/or retracted through gaps 107 and 108 , without deflection from deflector 112 , as shown for example in FIG. 1D .
Additionally, or alternatively, the spacer may be adjusted in size to decrease and/or increase the size of the gaps through which a shade is deployed and/or retracted. FIG. 3 is a diagram of an example shade storage and deployment system that includes a different spacer component than that shown in FIG. 1D and according to an implementation described herein. For example, as shown in FIG. 3 , spacer 310 may be oriented in the partial opening of recess 130 (e.g., via removal of spacer 110 and replacement with 310 ). Spacer 310 may be wider than spacer 110 enabling the gaps 307 and 308 to be smaller than gaps 107 and/or 108 . Additionally, or alternatively, if spacer 310 impedes the direct path of shade 103 to gaps 307 and/or 308 , deflector 312 may deflect shade 103 through gaps 307 and/or 308 . Shade 103 may be made of any material known in the art of suitable properties (e.g., strength, density, transparency, opaqueness, etc.) and may also, or alternatively, be made of a pliable and/or flexible material that is suitable to be controlled (e.g., bent, conformed, curved, deformed, etc.) upon contact with spacer 310 . For example, shade 103 may conform to a same or similar shape of spacer 310 when brought into contact with spacer 310 (“shaped controlled”). The controlling of a shape (e.g., bending, conforming, curving, deforming, etc.) of a shade via contact with a spacer is further described below with reference to FIGS. 9A-C and FIGS. 10A-C .
Additionally, or alternatively, the position of spacer 110 may be adjusted horizontally. FIG. 4 is a diagram of an example shade storage and deployment system that includes a spacer component in a different position that than shown in FIG. 1D and according to an implementation described herein. As shown in FIG. 4 , fastener 121 and corresponding fastener 113 may enable horizontal movement of spacer 110 , such that gaps 407 and 408 may be of different sizes relative to one another. Additionally, or alternatively, shade 103 may be deflected by deflector 112 through gap 407 if spacer 110 impedes the direct path of the free end of shade 103 through gap 407 .
Additionally or alternatively, the position of spacer 110 may be adjusted vertically. For example, in one non-limiting implementation, adjustment of the length of fastener 122 may enable vertical adjustment of spacer 110 , such that the outermost surface of spacer covering 111 may align with the outermost surface of horizontal covering 105 . In another implementation, spacer 110 may be configured to be adjusted vertically by other mechanisms, e.g., via adjustment of corresponding fastener 113 .
Additionally, or alternatively, the spacer may be configured to include electrical, electronic, and/or other elements. FIG. 5A is a diagram of an example attachment mechanism and spacer component of an example shade storage and deployment system according to an implementation described herein. For example, as shown in FIG. 5A , spacer 510 may include lighting element 514 (e.g., LED, halogen, fluorescent, neon, etc.). Lighting element 514 may be configured to be adjustable (e.g., via ball and socket connection, etc.) such that light emitted from lighting element 514 may be directed in a desired direction. Additionally or alternatively, lighting element 514 may be installed on the surface of and/or within spacer cover 511 . Additionally, or alternatively, other elements (e.g., camera, alarm, speaker, microphone, smoke detector, security device, sensor, etc.) may be installed on and/or within spacer 510 .
FIGS. 6A-6C are bottom elevational views of the example shade storage and deployment system of FIGS. 1A-1C . Additionally, or alternatively, as shown in FIGS. 6A-6C , the spacer may be configured to create gaps 609 a and/or 609 b . For example, spacer 110 may be oriented to create gaps 609 a and/or 609 b between spacer 110 and ceiling covering 640 . Gaps 609 a and/or 609 b may be adjustable in size in accordance with the techniques described herein. Gaps 609 a and/or 609 b may prevent the abutment of spacer 110 with ceiling covering 640 . The size of gaps 107 , 108 , 609 a , and/or 609 b are not intended to be limiting.
The figures and description herein generally show spacer 110 , gaps 107 , 108 , 609 a , 609 b , horizontal covering 105 , and/or vertical covering 106 as generally being rectangular shape for explanatory purposes. In other implementations, the shape of spacer 110 , gaps 107 , 108 , 609 a , 609 b , horizontal covering 105 and/or vertical covering 106 need not be so limited. Spacer 110 , gaps 107 , 108 , 609 a , 609 b , horizontal covering 105 and/or vertical covering 106 may be of any shape. For example, gaps 107 , 108 , 609 a , and/or 609 b may include curved, concave, convex, zip-zag, circular, elliptical, triangular, square, pentagular, hexangular, octangular shapes, etc. The shape of gaps 107 , 108 , 609 a , and/or 609 b may be formed by the shapes of spacer 110 , spacer covering 111 , horizontal covering 105 , and/or vertical covering 106 , which may be of any shape (e.g., curved, concave, convex, zip-zag, circular, elliptical, triangular, square, pentagular, hexangular, octangular, etc.).
For example, as shown in FIGS. 9A-C and FIGS. 10A-C , spacer 910 , 1010 may include convex and/or concave shapes. A curved shape of spacer 910 , 1010 (and/or a curved shape of a horizontal covering, vertical covering, gap, partial opening of recess, etc.) may enable spacer 1010 to make contact with a shade and, based on the application, may control the shape (e.g., curvature, contour, deformation, etc.) of the shade as deployed through a gap. Such a curved shade may improve the aesthetic features of a room (e.g., by preventing a visually unpleasing juncture from forming between the horizontal and/or vertical coverings and the spacer, etc.)
In other implementations, the shape of the spacer, horizontal covering, vertical covering, gap, and/or partial opening of the recess shown in FIGS. 9A-C and FIGS. 10A-C need not be so limited. For example, the spacer, horizontal covering, vertical covering, gap, and/or partial opening of the recess may include a shape and/or be oriented to maintain parallel edges between the spacer and the horizontal and/or vertical coverings (e.g., FIGS. 6A, 9A ). Said another way, the width of a gap may be generally constant, whether straight (e.g., FIG. 6A ) or curved (e.g., FIG. 9A ). Additionally or alternatively, the spacer, horizontal covering, vertical covering, gap, and/or partial opening of the recess may include a shape and/or be oriented such that the edges between the spacer and the horizontal and/or vertical coverings are not parallel. Said another way, the width of a gap may not be constant (e.g., FIGS. 10A-C ). Additionally, or alternatively, the dimensions of the spacer may be increased to eliminate gaps 609 a and/or 609 b , as shown for example, in FIG. 7 , which is a bottom elevational view of an example shade storage and deployment system according to an implementation described herein.
The described system may, for example, be installed according to the following method. One or more mount may be securely attached to at least a portion of a member of a structure. One or more tube may be removably and rotatably attached to the one or more mount. The one or more mount and/or one or more tube may be connected to a control mechanism configured to cause, at least, the tube to rotate. One or more shade may be securely attached to the one or more tube, such that a free end of the one or more tube may move away from and/or towards the tube when the tube is rotated. An attachment mechanism may be secured to at least a portion of a member of a structure. A spacer may be removably attached to the attachment mechanism via a fastener, to create one or more gap between the spacer and a ceiling base and/or a covering thereto. The spacer may be oriented to enable a free end of the one or more shade to move into and out of the one or more gap. The number and/or order of steps of the foregoing method are not intended to be limiting. Additionally, or alternatively, the method may include additional, fewer, and/or different steps and/or the steps may be performed in a different order than described herein. Additionally, or alternatively, one or more steps of the method may be repeated. | A window shade storage and deployment system includes a recess formed in a ceiling and an access panel. The recess houses a window shade movable between a retracted position and an extended position. The access panel is removably attached to a surface of the recess such that a visible surface of the access panel occupies substantially the same plane as a visible surface of the ceiling surrounding the recess. A gap is provided between an edge of the access panel and the ceiling. The gap enables the window shade to extend through the gap from the recess to the area below the visible surface of the ceiling when the window shade is in the extended position. The visible surface of the access panel and the visible surface of the ceiling include the same or a similar material such that the visible surface of the access panel and the visible surface of the ceiling are visibly substantially identical. | 4 |
FIELD OF THE INVENTION
[0001] The present invention relates in general to apparatus and methods for installing underground piping such as water and sewer mains, and in particular to apparatus and methods for installing such piping in narrow trenches.
BACKGROUND OF THE INVENTION
[0002] There are three methods commonly used for installing buried utility piping such as water and sewer mains. The “sale trench” method involves excavating a trench with its sides sloped at sufficiently shallow angles such that the potential risk of cave-ins is effectively eliminated. While providing optimal safety to workers, the safe trench method entails excavation of very large volumes of soil and the placing and compacting of corresponding large amounts of backfill. Because of the safe trench's sloped sides, this method disturbs and disrupts the use of a comparatively large surface land area.
[0003] The “trench shield” method reduces the necessary amount of excavation by using a heavy shield or enclosure, to protect workers in the trench. The shield is reinforced to resist forces and pressures that would be exerted against the shield in the event of a cave-in, making it safely feasible to use a trench that is narrower than a safe trench, and without needing the trench sides to be backsloped (or at least not as shallowly as a safe trench). The shield is moved along the length of the trench as new sections of pipe are added to die pipeline, to protect the work area surrounding each newly-added pipe section. The trench shield method thus provides safety to workers while reducing excavation and backfill requirements, but it has significant drawbacks nonetheless. Although, the trench can be narrower and less sloped than in the safe trench method, it still needs to be quite wide in order to accommodate the shield. Moving the shield, each time a new pipe section is added, entails a considerable amount of time, effort, and expense. These factors are exacerbated by the fact that the shield is necessarily quite heavy, especially if it is made long enough (as is preferable) to protect along the full length of a typical pipe section (which is commonly six meters long).
[0004] The third conventional method of installing underground piping is by inserting the pipe into a pre-bored hole. This method is very expensive, and its practical feasibility in a given situation will depend on a variety of variable factors (such as soil properties).
[0005] For the foregoing reasons, there is a need for pipe installation apparatus and methods that are practically and economically feasible in a broad range of field conditions, while requiring less excavation than conventional trenching methods and ensuring optimal worker safety. The present invention is directed to this need.
BRIEF DESCRIPTION OF THE INVENTION
[0006] In general terms, the present invention encompasses a method and apparatus for installing piping (especially jointed piping) in a narrow and substantially straight-walled trench, without need for workers to enter the trench. A first piping trench section is excavated to a desired length, using conventional equipment such as a track-mounted backhoe (also referred to as a trackhoe), with a bucket width typically in the range of 36 inches. Preferably, the bucket has a “spoon” attachment which farms a narrower secondary channel (or “sub-trench”) centered in the trench, for receiving piping. An equipment set-up area (or “working zone”), typically having a length of about 10 meters, is excavated at one end of the first trench section, for receiving the pipe installation apparatus of the present invention. The working zone is excavated in accordance with “safe trench” methods, to ensure the safety of workers operating the apparatus. Sand bedding is deposited into the trench (or, in the preferred embodiment, into the sub-trench), by workers and/or equipment at ground level. This process can be facilitated by having bedding sand deposited in small piles along the projected route of the trackhoe, prior to trench excavation. Upon completion, of excavation of a given section of trench, the hoe operator can scoop up some of the piled sand and deposit it in the trench (or sub-trench).
[0007] A first section of pipe is fed into the pipe installation apparatus, which is actuated so as to push the pipe section into the piping trench. The leading end of the pipe section is supported on a pipe sled which it pushes over the sand bedding as the pipe is pushed into the trench. The leading edge of the pipe sled has an upward curve or is otherwise configured to prevent the pipe from digging into the sand bedding, and at the same time serves to level and at least partially compact the sand bedding. When the apparatus has pushed the first pipe section into the trench, a second pipe section is fed into the apparatus and coupled to the first pipe section, and the apparatus then pushes the joined pipe sections further into the trench. Additional pipe sections are added until a pipe string has been laid along the full length of the first trench section.
[0008] A second trench section may then be excavated, along with an associated second working zone. The pipe installation apparatus is moved to the second working zone and is actuated to install a pipe string in the second trench section until it meets the pipe string previously laid in the first pipe section, and the two pipe strings are coupled to each other. The procedure is repeated as necessary to complete the full pipeline required for the project.
[0009] The method of the invention also provides for the installation of telescoping temporary spacers at locations along the finished pipeline where valves, tees, or other fittings need to be installed. Provision may he made for the safe installation of these fixtures during the trench excavation, by enlarging the trench to “safe trench” standards in the intended vicinity of fitting. The locations where temporary spacers need to be installed in the pipeline may be determined during pipeline installation operations using conventional measuring or surveying techniques. This may be facilitated by use of a known device such as a metering wheel or meter tally, mounted to the pipe installation apparatus, for measuring the length of pipe that has passed through the apparatus, thus enabling workers to make accurate determinations of where spacers should be installed. After a given string of piping and associated fittings has been positioned, a compressive force is applied to the string to firmly seat all joints between the various components. Most conveniently, this compressive force may he applied using the bucket of the trackhoe. The trench and all working zones may then be backfilled and compacted as required.
[0010] The present invention, also provides for a novel articulated packer apparatus especially adapted for compacting backfill in narrow trenches, such as in accordance with the method of the invention. The compaction apparatus may be independently self-propelled, or it may have a hydraulic drive system served by hydraulic fluid delivered by flexible hydraulic lines from the pipe installation apparatus. In preferred embodiments, the packer is remotely controlled so that it does not require an onboard operation, thereby further enhancing worker safety.
[0011] Accordingly, in a first aspect the present invention is an apparatus, for installing piping in a narrow trench.
[0012] In a second aspect, the invention is a packer for compacting backfill in a narrow trench.
[0013] In a third aspect, the invention is a method for installing piping in a narrow trench.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] Embodiments of the invention will now be described with reference to the accompanying figures, in which numerical references denote like parts, and in which:
[0015] FIG. 1 is a perspective view of the pipe installation apparatus in accordance with a first embodiment of the invention.
[0016] FIG. 2 is a plan view of the apparatus- of FIG. 1 , showing the outriggers in a stowed position.
[0017] FIG. 3 is a plan view as in FIG. 2 , but with the outriggers in a deployed position.
[0018] FIG. 4 is an elevational cross-section showing a pipe being led through the pipe drive mechanism of the apparatus of FIG. 1 .
[0019] FIG. 5A is an oblique partial section showing a pipe being fed through the pipe drive mechanism shown in FIG. 4 , and illustrating the spring-actuated biasing means of the mechanism.
[0020] FIG. 5B is an oblique partial section as in FIG. 5A illustrating the actuation of the biasing means when a pipe coupling passes through the pipe drive mechanism.
[0021] FIG. 6 is a plan view of the apparatus of FIG. 1 positioned in a working zone and pushing a partially assembled pipe string into a trench.
[0022] FIG. 7A is a cross-section through a trench incorporating a secondary channel, shown with an optional laser support structure spanning the trench.
[0023] FIG. 7B is a cross-section through a working zone, incorporating a secondary excavation for housing the pipe installation apparatus of the present invention.
[0024] FIG. 8A is a side elevation of the apparatus in operation as in FIG. 6 .
[0025] FIG. 8B is a side elevation of the leading end of a pipe string positioned in a pipe sled as shown in FIG. 6 .
[0026] FIG. 9 is a cross-section through a piping trench during backfilling operations using a remote-controlled articulated packer in accordance with the invention.
[0027] FIG. 10 is a side elevation of the packer shown in FIG. 9 .
[0028] FIG. 11 is an elevational cross-section of a pipe drive mechanism in accordance with a second embodiment of the invention.
[0029] FIG. 12 is a side elevation of the pipe drive mechanism of FIG. 11 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0030] Referring to FIGS. 1 , 2 , and 3 , the pipe installation apparatus of the invention (generally designated by reference character 10 ) has a base structure 20 adapted to rest on a generally level surface, with a transverse bulkhead 30 mounted to base structure 20 at a medial point along the length of base structure 20 . In the Figures and in this specification, bulkhead 30 is representatively shown and referred to as a solid, plate-like structure, but that particular configuration is not essential to the invention. Bulkhead 30 could be of any suitably rigid construction, including an open framework. Accordingly, references herein to bulkhead 30 are to be understood in a non-restrictive sense, and to include transverse frames of other constructions.
[0031] Bulkhead 30 has a front side 30 F and a rear side 30 R. The configuration and construction of base structure 20 may take any form suitable for the functions described herein. In the illustrated preferred embodiment, base structure 20 is of generally rectangular outline (as viewed in plan), with a front end 20 F and a rear end 20 R. Base structure 20 has a pair of spaced side rails 21 extending between, a front frame 22 F having a front frame opening 23 F, arid a rear frame 22 R having a rear frame opening 23 R. Openings 23 A and 23 B are sized to suit the pipe to be laid using apparatus 10 . Base structure 20 has a longitudinal axis extending between front end 20 F and rear end 20 R, approximately midway between side rails 21 .
[0032] Front frame 22 F and rear frame 22 R each incorporate support legs 24 , which optionally may include adjustment means (not shown) for adapting to uneven supporting surfaces. The adjustment means could comprise manually-operated screw-type or ratchet-type jacks, hydraulic cylinders, or any other suitable mechanism, various, types of which are well known in the art. The overall size and proportions of base structure 20 will depend on selected operational design parameters. In preferred embodiments, however, base structure 20 will be configured such that it can be readily transported in the box of a half ton truck.
[0033] Bulkhead 30 has a pipe opening 32 generally aligned with front frame opening 23 F and rear frame opening 23 R. Mounted in association with bulkhead 30 is a pipe drive mechanism, for engaging a pipe section 70 passing through pipe opening 32 and advancing it toward the front end 20 F of base structure 20 and through front frame opening 23 F. The pipe drive mechanism may take any of several different forms. In the embodiment shown in FIGS. 1-4 , the pipe drive mechanism includes a plurality of drive wheels 34 spaced radially around pipe opening 32 in association with either the front side or the rear side of bulkhead 30 . In the preferred embodiment (and as best seen in FIG. 4 ), each drive wheel 34 has its awn hydraulic drive motor 36 . Drive wheels 34 preferably will be rubber-tired, to facilitate effective tractive engagement with pipe 70 without causing damage to the outer surfaces of pipe 70 .
[0034] The pipe drive mechanism shown in FIGS. 1-4 has a total of four drive wheels, each with its own hydraulic drive motor 36 . However, other pipe drive configurations are readily conceivable. To provide non-limiting examples of alternative configurations, the pipe drive mechanism could have three drive wheels, rather than four as shown. Another alternative embodiment could have four pipe-engaging wheels as shown, but with only two of the wheels being driven (preferably radially opposing each other) and with the other two wheels acting as idlers winch help guide the pipe 70 through pipe opening 32 . Other embodiments could use only a single drive wheel. A further embodiment (shown in FIGS. 11 and 12 , and described in detail later in this specification) would have six drive wheels mounted in pairs, with each pair of wheels driven by a single hydraulic motor by means of a pair of drive chains.
[0035] Simple embodiments of the pipe drive mechanism may have a fixed configuration for handling pipe of a specific diameter. In preferred embodiments, however, the pipe drive mechanism incorporates wheel adjustment means for adapting to different pipe sizes. In the embodiment shown in FIGS. 1-4 , 5 A, and 5 B, the wheel adjustment means is provided by mounting each motor 36 on slide arm 38 which slides within a sleeve 40 which in turn is pivotably mounted to a bracket 41 connected to bulkhead 30 . The radial position of slide arm 38 within sleeve 40 may be controlled by means of set screws or bolts 44 as illustrated, or by any other suitable and conventional means. The wheel adjustment means could of course be provided in various other forms using well-known technology. For example, a hydraulic or pneumatic cylinder could be provided for adjusting the radial position of each drive wheel 34 to accommodate different pipe sizes.
[0036] As illustrated in FIGS. 5A and 5B , the pipe drive mechanism preferably includes biasing means for biasing drive wheels 34 against a pipe 70 passing through pipe opening 32 so as to optimize the grip or traction between drive wheels 34 and pipe 70 . In the Illustrated embodiment, the biasing means for each drive wheel 34 is provided in the form of a compression spring 42 disposed between sleeve 40 and bulkhead 30 , radially outboard of the associated bracket 41 . When there is no pipe passing through pipe opening 32 , spring 42 biases wheel 34 toward (or even against) front face 30 F of bulkhead 30 , with the clear space between opposing drive wheels 34 being somewhat less than the diameter of the pipe to be installed. Therefore, when a pipe section 70 is then passed through pipe opening 32 in a direction toward front frame opening 23 F, it will be tractively engaged by drive wheels 34 (which are being rotated by their respective hydraulic motors 36 ).
[0037] Springs 42 thus promote and maintain effective traction between drive wheels 34 and pipe 70 . At the same time, they provide resiliency to accommodate imperfections in pipe 70 (for example, out-of-roundness), and to accommodate passage of pipe couplings 72 at connections between pipe sections where, as is common, the outer diameter of the coupling 72 is greater than that of pipe 70 . As shown in FIG. 5B , the passage of a coupling 72 through pipe opening 32 is accommodated by additional compression of spring 42 , which remains effective to keep drive wheels 34 in tractive engagement with pipe 70 (and coupling 72 ).
[0038] Persons skilled in the art of the invention will readily appreciate that other effective biasing means may be devised in accordance with known principles and technologies, without departing from the essential concepts of the present invention.
[0039] FIGS. 11 and 12 illustrate an alternative embodiment of the pipe drive mechanism having three pairs of drive wheels, with each pair of wheels being driven by a single hydraulic motor. A pair of spaced-apart upper wheels 34 U are rotatably mounted in coplanar relation to a suitable upper beam structure 190 U positioned above pipe opening 32 and extending between bulkhead 30 and a suitable upper support member 192 U connected to or forming part of base structure 20 . As shown in FIG. 11 , upper wheels 340 are radially oriented relative to pipe opening 32 . Each upper wheel 34 U has a coaxially-mounted upper wheel sprocket 194 U rotatable with upper wheel 34 U. An upper motor support structure 1950 U is mounted to upper beam 190 U at a point between upper wheels 34 U, and supports an upper hydraulic motor 361 U which tarns an upper drive sprocket 196 U lying in the same plane as upper wheel sprockets 194 U. A continuous upper drive chain 198 U is disposed around upper wheel sprockets 196 U and upper drive sprocket 196 U such that actuation of upper motor 36 U will cause rotation of upper wheels 34 U.
[0040] Upper motor support structure 195 U may be of any suitable construction, and is preferably adapted to include or accommodate motor position adjustment means for adjusting the position of upper motor 36 U relative to upper motor support structure 195 U, to facilitate tensioning of upper drive chain 198 U as may be required. In FIG. 12 , the adjustment means is conceptually shown as incorporating an arm to which upper motor 36 U is mounted and which is slidable within a sleeve member connected to upper beam structure 190 U. However, persons skilled in the art will appreciate that the motor position adjustment means could take various other forms in accordance with well-known design principles and techniques.
[0041] In simple embodiments, upper beam structure 190 U can be rigidly connected to its end supports (i.e., bulkhead 30 and upper support member 192 U), with its position being set to accommodate a specific size of pipe 70 . In preferred embodiments, though, upper beam 190 U is mounted to its end supports using suitable wheel height adjustment means 199 , thus allowing the radial position of upper wheels 34 U, relative to pipe opening 32 , to be adjusted to suit different sizes of pipe 70 . In FIG. 12 , wheel height adjustment means 199 is shown as comprising an upstand connected to upper beam 190 U and slidable within a capped tubular sleeve connected to bulkhead 30 (or upper support member 192 U), with a coil spring disposed between the upstand and the cap of the sleeve to bias upper wheels 34 U radially toward a pipe 70 passing through pipe opening 32 . A bolt 44 or pin passes through a hole (or holes) in the sleeve and through a vertically slot (or slots) in the upstand, such that the upstand is retained by and movable within the sleeve (to the extent allowed by the slots). Multiple holes can be provided in the sleeve to facilitate adjustment of wheel height adjustment means 199 to suit different pipe sizes.
[0042] The construction shown and described in connection with wheel height adjustment means 199 is for purposes of example only. Persons skilled in the art will appreciate that wheel height adjustment means 199 could take various other forms in accordance with well-known design principles and techniques.
[0043] Below upper beam structure 190 U and pipe opening 32 , a pair of lower beam structures 190 L extend between bulkhead 30 and a suitable lower support member 194 L connected to or forming part of base structure 20 . A pair of spaced-part lower wheels 34 L are ratably mounted to each lower beam 190 L in substantially the same fashion as described in connection with upper wheels 34 U. Each lower wheel 34 L has a coaxially-mounted lower wheel sprocket 194 L, rotatable with lower wheel 34 L. A lower motor support structure 195 L is mounted to each lower beam 190 U at a point between lower wheels 34 L, and supports a lower hydraulic motor 36 L which turns a lower drive sprocket 196 L lying in the same plane as lower wheel sprockets 194 L. A continuous lower drive chain 198 L is disposed around lower wheel sprockets 196 L and lower drive sprocket 196 L such, that actuation of lower motor 36 L will cause rotation of lower wheels 34 L.
[0044] As best seen in FIG. 11 , the two pairs of lower wheels 34 L are preferably disposed on either side of pipe opening 32 in a canted radial orientation, such that all upper wheels 34 U and lower wheels 34 L can tractively engage a pipe 70 passing through pipe opening 32 , with all wheels' planes of rotation passing through or close to the longitudinal axis of pipe 70 , thus optimizing tractive efficiency. In alternative embodiments, however, the planes of the two pairs of lower wheels 34 L could both be vertical.
[0045] Although three sets of wheels are used in the embodiment shown In FIGS. 11 and 12 , it would of course be feasible to use more than three sets. However, the use of three sets of wheels is particularly preferred since that configuration helps to ensure that all wheels will have substantially uniform contact with, pipe 70 . Maximum tractive effectiveness with respect to pipe 70 is achieved by driving all wheels 34 U and 34 L, but this is not essential in one variant, only lower wheels 34 L are driven, with upper wheels 340 being idlers; in another variant, only upper wheels 34 U are driven, with lower wheels 34 L being idlers.
[0046] Persons of ordinary skill in die art will appreciate that other variants of the drive mechanism of FIGS. 11 and 12 may be readily devised without departing from the principles of the present invention. To provide one non-limiting example, pulleys and drive belts could be used instead of sprockets and drive chains.
[0047] The operation of the pipe drive mechanism to advance pipe toward and through front frame opening 23 F will necessarily result in an opposite reactive force acting against base structure 20 . Accordingly, anchorage means must be provided to resist this reactive force in order to prevent rearward displacement of the apparatus 10 (i.e., to transfer the reactive force to the ground in the vicinity of apparatus 10 ). It may be possible in some operative circumstances, when the magnitude of the reactive force is small, for the anchorage means to be effectively provided by frictional or mechanical resistance between base structure 20 and the surface upon which it rests. In preferred embodiments, however, and as shown in FIGS. 1 , 2 , 3 , and 6 , the anchorage means is provided in the form of a pair of outriggers 26 , one on either side of base structure 20 . One end of each outrigger 26 is mounted to base structure 20 (preferably, but not necessarily, near front end 20 F thereof) so as to be pivotable about a vertical axis. The other end of each outrigger 26 has an anchorage member 27 (such as a steel plate or blade) adapted to penetrate into and to be retained within a soil mass. Each outrigger 26 has a hydraulic, cylinder 28 extending; from a point near anchorage member 27 to a selected connection point on base structure 20 . Actuation of hydraulic cylinder 28 is thus effective to move outrigger 26 in a generally horizontal plane between a stowed position (as shown in FIG. 2 ) and a deployed position (as shown in FIGS. 3 and 6 ). Effective result: have been achieved using hydraulic cylinders 28 having a 2-inch bore and an 8-inch stroke, with a working pressure of 3,000 pounds per square inch. However, hydraulic cylinders with other characteristics may be suitable or appropriate depending on site conditions arid desired operational, criteria.
[0048] It will be appreciated that the anchorage means described above and illustrated in the Figures represents an exemplary embodiment, and other effective anchorage means may be devised without departing from the principles of the present invention.
[0049] In simpler embodiments of the invention, pressure hydraulic fluid for actuating the hydraulic wheel motors and hydraulic cylinders of the anchorage means could be provided from a source external to apparatus 10 . In preferred embodiments however, apparatus 10 is a self-contained unit, and therefore includes a power control system, conceptually indicated in FIGS. 1 , 2 , 3 , and 6 as comprising a power module 50 and a control module 60 . In the preferred embodiment, power module 50 incorporates a gas or diesel engine (with various accessories including a fuel tank), a hydraulic pump which is driven by the gas or diesel engine, and a hydraulic fluid reservoir. To provide one non-limiting example, beneficial results have been achieved using a 20-horsepower gas engine driving a Vickers™ Model 45D50A1A122R hydraulic pump with 1-inch lines. Control module 60 incorporates hydraulic system accessories such as manifolds, valves, and valve actuators for controlling flow of hydraulic fluid between the fluid reservoir and hydraulic motors 36 associated with drive wheels 34 , via hydraulic hoses 37 . In the preferred embodiment, power module 50 and control module 60 are mounted to base structure 20 in association with auxiliary rails 21 extending between rear frame 22 R and bulkhead 30 , but other mounting arrangements are possible without departing from the essential concept of the invention.
[0050] Persons skilled in the field of the invention will be sufficiently familiar with the principles of power systems and hydraulic drive and control systems so as to be readily able to devise one or more embodiments of a power module 50 and a control module 60 suitable for use with the present invention, without need to set out detailed hydraulic schematics or component particulars for purposes of this patent specification.
[0051] FIGS. 6 , 7 A, 7 B, A, and 8 B illustrate how the apparatus 10 of the invention may be deployed in the field for purposes of installing underground piping. As shown in FIG. 7A , a piping trench 80 is excavated along a desired path, using suitable equipment such as a conventional trackhoe. As may be seen from FIG. 6 and in particular from FIG. 7A , trench 80 may be comparatively narrow, with vertical or near-vertical sidewalls 80 W if the soil is sufficiently cohesive. As indicated by reference characters 81 , it may in some cases be desirable to backslope the upper regions of sidewalls 80 W. If soil characteristics are such that sidewalls 80 W require some amount of backsloping, the backslope angle can generally be significantly sleeper than would be warranted when installing pipe using safe trench methods.
[0052] In preferred embodiments of the method, a secondary channel 82 is excavated at the base of trench 80 . Secondary channel 82 may be formed using any suitable method. Preferably, secondary channel 82 will be formed concurrently with trench 80 , using a trackhoe with an auxiliary blade or “spoon” permanently or removably attached to, and extending downward from, the cutting edge of the trackhoe bucket. The geometry of the “spoon” will be selected to suit the desired cross-sectional dimensions of secondary channel 82 , which, in turn will depend on the size of pipe to be installed in secondary channel 82 . As desired, a different, size of “spoon” may be used for each pipe size; alternatively, a given size of “spoon” may be used for a range of pipe sizes.
[0053] The depth of trench 80 (and, in the preferred embodiment, secondary channel 82 ) needs to be controlled within reasonably close tolerances in order to ensure that the installed pipeline will be at the intended grade and slope. This is accomplished in accordance with well-known level surveying methods, preferably using a stationary surveyor's laser 200 . For this purpose, and as may be seen in FIG. 7A , a laser support structure 210 may be provided at a convenience location, spanning trench 80 , for supporting the laser 200 , which emits a visible beam in a constant horizontal plane. As trench excavation proceeds, a worker carrying a surveyor's rod of suitable length holds the rod on the bottom of trench 80 in location as directed by the trackhoe operator. The laser beam intercepts the scale on the rod, enabling the trackhoe operator to determine the current depth of trench 80 , and to determine the extent to which additional excavation may be required.
[0054] To prepare for use of the pipe installation apparatus 10 of the present, invention, a working zone 84 is excavated at the end of trench 80 , generally as shown in FIGS. 6 and 7 B. The length of working zone 84 (as measured parallel to trench 80 ) will preferably be in the range of 10 meters, but in general will be selected to suit various practical factors including the dimensions of apparatus 10 and the desired extent of worker access space around apparatus 10 . Working zone 84 has sidewalls 84 W which are backsloped in accordance with “safe trench” methods as appropriate to suit soil conditions. A machine pit 88 , with sidewalls 88 W, is excavated at the base of working zone 84 to accommodate apparatus 10 , leaving a generally level access area 86 adjacent to apparatus 10 as appropriate. Machine pit 88 is excavated within reasonable tolerances to facilitate effective engagement of anchorage members 27 with sidewalls 88 W. As best seen in FIG. 7B , machine pit 88 is excavated to art appropriate depth such that once apparatus 10 is positioned therein, front frame opening 23 F, rear frame opening 23 R, and pipe opening 32 of bulkhead 30 will be in general alignment, both horizontally and vertically, with the base of trench 80 (or, in the preferred, embodiment, with secondary channel 82 ).
[0055] After working zone 84 and machine pit 88 have been excavated, apparatus 10 is positioned in machine pit 88 as shown in FIGS. 6 and 7B . Outriggers 26 are then deployed, by actuation of hydraulic cylinder 28 , such that their anchorage members 27 penetrate and securely engage sidewalls 88 W of machine pit 88 . As shown In FIGS. 7A and 8B , a layer of sand bedding 110 is deposited in the bottom of trench 80 (or, in the preferred embodiment, secondary channel 82 ). A first pipe section 70 A is fed manually through rear frame opening 23 R and pipe opening 32 so as to engage drive wheels 34 , which in turn advance first pipe section 70 forward through front frame opening 23 F. Leading end 72 A of first, pipe section 70 A is then engaged with a pipe sled 90 as shown in FIGS. 6 , 7 A, and 8 B. Pipe sled 90 has a sole plate 92 adapted for sliding over sand bedding 110 , with a contiguous upturned prow member 94 that prevents pipe sled 90 from digging downward into sand bedding 110 . Pipe sled 90 also has a sleeve or bracket 96 , of any suitable configuration, for receiving and retaining leading end 72 A of first pipe section 70 A.
[0056] The apparatus 10 is then activated so as to advance first pipe section 70 A and pipe sled 90 into trench 80 , with pipe sled 90 acting to level and to some extent compact sand bedding 110 as it passes thereover, and with the horizontal reactive force induced by this operation being transferred into sidewalls 88 W of machine pit 88 through outriggers 26 and anchorage members 27 . Pipe sled 90 may be suitably heavy or may have supplemental weighting to enhance its effectiveness for purposes of levelling and compacting sand bedding 110 .
[0057] When the trailing end 74 A first pipe section 70 A approaches rear frame opening 23 R, the forward advance of first pipe section 70 is temporarily stopped so that a second pipe section 70 B can be coupled to trailing end 74 A of first pipe section 70 A. The apparatus 10 is then reactivated so as to advance the pipe string (comprising first and second pipe sections 70 A and 70 B) further into trench 80 . Hits mode of operation is carried on, with additional pipe sections being added as required, until leading end 72 A of first pipe section 70 A has advanced to a desired final position. At that stage, apparatus 10 may be re-positioned in a second working zone 84 a selected distance back along trench 80 . A second pipe string is then advanced into the trench until it meets and is coupled to the trailing edge of the first pipe string. This procedure is repeated as required until the entire pipeline required for the project has been laid in trench 80 .
[0058] The distance between working zones 84 will be selected to suit a variety of factors, including but not limited to the size and weight of pipe being installed and the mechanical capabilities of the particular apparatus 10 being used. As a general rule, the power required to advance a pipe string into trench 80 will be greater for heavier pipe sections, and will increase as the length of the string increases. It has been found that working zone intervals in the range of 50 to 100 meters are typically sufficient for installing 6-inch to 12-inch plastic wafer mains, using an apparatus 10 compact enough to be transported on a half-ton truck. However, larger or smaller working zone intervals may be practical or desirable for particular combinations of variable design factors and project requirements.
[0059] At one or more locations along the length of the pipeline being installed, it will commonly be necessary to install valves, tees, cleanouts, or other fittings. To accommodate such fittings, the method of the invention provides for the installation of collapsible spacers (not shown) in such locations. The spacers may be of any suitable construction. In the preferred embodiment, however, each spacer comprises a first pipe section and a smaller second pipe section which can slide in telescopic fashion within the first pipe section. Preferably; each pipe section has a linearly-arrayed series of pin holes for receiving a retainer pin. The second pipe section is positioned as desired within the first pipe section, with at least one pin hole, of each pipe section being In alignment, whereupon one or more suitable retainer pins can be dropped through the aligned pin hole(s), thus temporarily fixing the length of the spacer (to suit the length of the fitting to be installed in the, spacer location). One end of the spacer will be a “male” end and the other end will be a “female” end, adapted for engagement with typical pipe sections 70 being laid in trench 80 (or secondary channel 82 ).
[0060] The collapsible spacers thus make it possible to install the full length of the pipeline, using the apparatus and method of the present invention, in a continuous fashion without needing to interrupt pipe-laying operations to install valves and tees and the like. After the pipeline has been laid out incorporating all required spacers, workers can enter a secondary “safe” working zone which has been excavated around each spacer to install the required fitting. The spacer is “collapsed” by removing the retainer pin(s) and then telescoping the two spacer sections, thus disengaging the spacer from adjacent pipe sections 70 to Which the spacer had been temporarily connected. The required valve or other fitting is then connected between the adjacent pipe sections 70 .
[0061] After all spacers have been replaced with their corresponding valves, fees, or other fittings, the entire pipeline string is ready to be backfilled. Prior to that step, however, the connections between the various components are preferably made more secure by applying a compressive force to the string, so as to firmly seat all joints. Such a compressive force may be applied using the bucket of a trackhoe.
[0062] After all required pipeline strings have been positioned and connected as desired (and after the pipe installation, apparatus 10 has been removed), all trenches 80 , secondary channels 82 , working zones 84 , and machine pits 88 may be backfilled and compacted as appropriate. In many if not most cases, it will necessary or desirable for the backfill 115 to be compacted to specified densities to prevent excessive settlement as backfill 115 consolidates over time, and methods and equipment for achieving such backfill densities are well known, in the interests of worker safety, however, it is desirable be able to compact, backfill 15 in narrow trenches 80 without the need for workers to descend into them.
[0063] For this reason, compaction of backfill 115 in trenches 80 is preferably carried out using a remote-control led articulated packer 120 as illustrated in. FIGS. 9 and 10 . In the preferred embodiment, packer 120 has a front section 120 A plus a rear section 120 B of basically construction. Front section 120 A has a roller drum 122 A mounted to a peripheral frame 126 A by means of suitable bearings 124 ; similarly, rear section 120 B has a roller drum 122 B mounted to a peripheral, frame 126 B by bearings 124 . Frames 126 A and 126 B are coupled by a suitable articulation linkage (conceptually indicated by reference character 160 ) whereby front and rear sections 120 A and 120 B may swivel relative to each other about a substantially vertical axis Z. The articulation linkage may incorporate steering means for selectively controlling relative swivelling of front and rear sections 120 A and 120 B. The steering means preferably will include at least one hydraulic steering ram, although other types of steering mechanisms may also be used. Although not essential, linkage 160 preferably will also provide for at least a limited degree of swivelling about a transverse horizontal axis.
[0064] Roller drums 122 A and 122 B are fabricated of steel plate in a fashion similar to rollers of known compaction equipment, with a continuous cylindrical outer plate 123 arid circular side plates 125 enclosing an inner chamber 127 that may be filled with ballasting material (such as water), in the illustrated embodiment, side plate 125 on roller drum 122 A is inset a suitable distance from the edge of outer plate 123 to define a a recess 125 F in which a suitable packer drive/braking mechanism (schematically indicated by reference character 150 ) may be disposed. The packer drive/braking mechanism could take a variety of forms, only a few of which are described or illustrated herein.
[0065] In preferred embodiments, the packer drive mechanism incorporates a reversible hydraulic motor having a “neutral” mode. In the preferred embodiment, the output shaft of the hydraulic motor is fitted with a drive sprocket that engages a drive chain attached to the outer lace of side plate 125 (such as by welding) in a circular configuration concentric with the drum's axle, thereby causing the drum to rotate in a selected direction. Alternatively, a sprocket, could be concentrically mounted to side plate 125 , and driven by means of a drive chain disposed around the hydraulic motor's drive sprocket and the sprocket mounted to side plate 125 .
[0066] The packer braking mechanism may work on principles analogous to automotive dram brakes, with one or more brake, shoes (with appropriately curved brake pads) that may be urged radially outward into contact with the inner face of outer plate 123 within recess 125 F so as to retard and stop the rotation of the associated roller drum.
[0067] The sizes of roller drums 122 A and 122 B and their associated frames 126 A and 126 B will be determined to suit the width of trench 80 in which packer 120 is intended to be operated, as well as the roller mass required to achieve the desired level of backfill compaction. Satisfactory results have been achieved using roller drums having diameters of approximately 42 inches.
[0068] In the embodiment shown in FIG. 10 , front section 120 A of packer 120 has a platform 165 disposed above roller drum 122 A and supported from frame 126 A by suitable structural support members 132 . The purpose of platform 165 is to support auxiliary components (schematically indicated by reference character 170 ) associated with packer drive/braking mechanism 150 and its remote control system. In preferred embodiments, the auxiliary components will include a hydraulic pump operably connected to the hydraulic motor of the packer's drive system, and a gas motor for driving the hydraulic pump.
[0069] The remote control system for the packer drive/braking mechanism 150 may be either a wireless (e.g., radio-controlled) or hard-wired system, in accordance with, well-known technology. In alternative embodiments, the packer may have a seat (and possibly a cab) for a riding operator, rather than being remotely controlled.
[0070] In preferred embodiments, as shown in FIG. 10 , packer 120 has a second platform 130 carrying a water tank (schematically indicated by reference character 140 ), which may be used for adding water to backfill in the trench as may be required to achieve desired or required backfill compaction standards.
[0071] Also in preferred embodiments, packer 120 may be equipped with an adjustable “dozer” blade at either or both ends of packer 120 (as schematically indicated by reference characters 180 A and 180 B in FIG. 10 ). Dozer blades 180 A and 180 B will ideally be adjustable for both blade height and blade angle, by means of suitable hydraulic rams operably connected to a hydraulic pump included in auxiliary components 170 . This pump could be the same pump that serves the hydraulic motor associated with packer drive/braking mechanism 150 , or it could be a dedicated pump serving only the dozer blades.
[0072] It may be seen from the foregoing that the present invention enables she installation of utility in narrow and substantially straight-walled trenches, thus requiring considerably less excavation and backfill than in conventional pipe installation methods, while eliminating or limiting the need for workers to enter the trenches.
[0073] It will be readily appreciated by those skilled in the art that various modifications of the present invention may be devised without departing from the essential concept of the invention, and all such modifications are intended to come within the scope of the present invention.
[0074] In this patent document, the word “comprising” is used in its non-limiting sense to mean that items following that word are included, but items not specifically mentioned are not excluded. A reference to an element by the Indefinite article “a” does not exclude the possibility that more than one of the element is present, unless the context clearly requires that there be one and only one such element. | In a method for installing underground piping, a pipe installation apparatus is temporarily positioned at one end of a pipe trench, in which bedding sand has been placed. The apparatus has a pipe opening through which pipe can pass, and a plurality of rubber-tired pipe wheels arrayed around and biased radially inward toward the pipe opening. At least one wheel is a motor-operated drive wheel. A section of pipe introduced into the pipe opening will be tractively engaged by the drive wheels and pushed through the pipe opening and into the trends The drive motors are disengaged as required for connection of additional pipe sections, or for placing temporary spacers in the pipeline to facilitate subsequent installation of required pipeline fittings. The leading end of the pipeline engages a sled which rides over and levels die bedding sand while preventing the pipe from digging into the sand. The need for workers to enter the pipe trench is thus reduced or eliminated, making it possible to safely install piping in steep-walled trenches. | 4 |
This application is a continuation in part of my co-pending application Ser. No. 638,530 filed Dec. 8, 1975, now abandoned.
BACKGROUND OF THE INVENTION
Any person, skilled or unskilled, finds it difficult to establish the correct location of the required pleats on a length of fabric without the use of some type of mechanical aid. This is so because for an individual to correctly measure for pleated drapes, the total width of each of the drapes is measured and the number of pleats desired is calculated. Then, the width of each pleat is figured, and the spacing between adjacent pleats is determined. This procedure is often inaccurate whereby several size adjustments are often made in order to achieve the proper pleat width and spacing between the pleats. Moreover, even after corrections have been made it is not always certain that the calculation made is precise and that the correct pleated drape measurements will be made.
The mechanical aids previously proposed to assist the drapery maker were complex and cumbersome. Applicant's fabric pleater guide as described in his U.S. Pat. No. 3,667,677 was an improvement in that it did succeed in simplifying the drapery making procedure, however, the present invention has reduced the mechanical drapery making aid to its simplest form and yet this device operates effectively and accurately.
SUMMARY OF THE INVENTION
The present invention relates to a portable lightweight fabric pleater guide which is so simple to operate that it can be used by both the unskilled beginner and skilled professional drapery maker with successful results.
It is an object of the present invention to provide a drapery pleat loop spacer that will produce accurately reproducible primary pleat loops of uniform size, and also provides for a selective adjustment for the various spacings between the primary pleat loops.
Another object of the present invention is to provide the drapery maker with the option of positioning the primary pleat loops by either stapling, marking or pinning.
An object of the present invention is to provide a drapery pleat loop spacer with a fixed finger, an elongated base, an adjustable relatively broad finger, and a stapler device to effect the positioning of the primary pleat loops.
It is a further object of the present invention to provide a drapery pleat loop spacer with a fixed marking finger on an elongated calibrated base, and a separately assembled adjustable broad finger.
Another object of the present invention is to provide the drapery maker with an option of positioning the primary pleats by marking, pinning or stapling.
The pleat loop spacer constructed in accordance with the teachings of my invention is portable and can be provided with a metrically calibrated scale on its base member so that the pleat loop spacings may be quickly and easily determined.
It is still another object of the present invention to provide a pleater device for draperies in which the material panel can be spread out flat on a flat surface and does not have to be handled by the operator while positioning pleats. Thus, the panel can be completely finished and the pleats positioned thereafter, starting from either the right or the left hand side of the panel. It should be evident that it is not necessary with my pleater device to fold the fabric in half and the first pleat positioned at the centerfold thereof, as was the procedure in previous fabric pleater guide devices.
A further object of the present invention is to provide a pinch pleat former which when inserted in the primary pleat loop and centered over the seam of the loop automatically and precisely divides the loop into three equal folds forming what is commonly known as a pinch pleat.
Another object of the present invention is to provide a drapery pleat spacer and former which can be inexpensively manufactured out of plastic, metal or hard board stampings and which can be used effectively by the beginner and professional drapery maker.
In order that the invention will be more clearly understood, it will now be disclosed in greater detail with reference to the accompanying drawings, in which:
FIG. 1 is a front elevational view of the fabric pleater guide device constructed in accordance with the teachings of my invention.
FIG. 1a is an exploded side view of the device shown in FIG. 1
FIG. 2 is a front elevational view of the device which is similar to FIG. 1, but shown as used with drapery material in a first step of the procedure.
FIG. 3 is a front elevational view of the device similar to FIG. 2 but with a further step in the procedure of making drapes.
FIGS. 4, 4a and 4b are top plan, side view and end view of a pleat former that is utilized with the present device for making pinch pleats in drapes.
FIG. 5 is a perspective view of the pleat former shown in FIGS. 4, 4a and 4b prior to its insertion in a drapery primary loop.
FIG. 6 is a perspective view of the pleat former inserted within the drapery loop and positioned for forming a precise pinch pleat.
FIG. 7 is an alternate embodiment of the present invention in which only one fixed and one movable leg is shown, and which incorporates a long throw stapler for determining the precise locations of the drapery pleats.
FIG. 8 is a front elevational view of another embodiment of my present invention showing a fabric pleater guide having three fingers in which the end finger is in a fixed position.
FIG. 9 is a top plan view of the fabric pleater guide shown in FIG. 8.
FIG. 10 is a side elevational view of the fabric pleater guide shown in FIG. 8, and
FIGS. 11-13 are diagrammatic views showing the mode of operation of the fabric pleater guide illustrated in FIGS. 8-10.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The drapery loop spacer device is shown generally by the reference numeral 10 and constitutes a base member 11 having generally perpendicular fingers, such as a broad fixed finger 12 and a relatively narrow fixed finger 14. The base 11 is provided with a measuring scale which may be in the metric system, and adjustable broad finger 16 having an index pointer 17. As seen in FIG. 1a the drapery loop spacer device is assembled in a tongue and groove arrangement in which a bolt 20 is inserted through the slot 21 and screw connected to the restraining nut 22 that is housed in the groove 23 at the surface of the base 11 behind the calibrated area 18. It should be observed that the bolt 20 can be moved along the slot 21 to a selected position so that the finger 16 is adjustable laterally in order to position the same for the correct drapery pleat loop spacing.
In using the drapery loop spacer device 10, the number of pleat loops in a given length of fabric is determined and the adjustable finger 16 is adjusted and set for the required distance between the pleat loops. Then, in order to prepare the heading of the drapery panel, the material is folded in half on the wrong side to establish the center C. Thereafter in order to begin forming and positioning pleat loops the material is held with the stiffening edge toward the drapery maker with the center fold on her left, and the remainder of the material flowing to the right. As shown in FIG. 2 the pleat loop spacer 10 is held with the fingers 12, 14, and 16 pointing away from the operator. The broad finger 12 is then slipped into the center fold of the material C with the latter positioned along the finger edge 12a. Thereafter, both layers of material are firmly pulled to the right under fingers 14 and 16 as seen in FIG. 2. A pin 15 is now inserted through both layers of material about 11/2 inches to the right of the marking finger 14 to thereby hold both layers taut. At this point the precise position of the pleat loop can be determined by three different methods as follows:
1. Marking by means of visible marking means as close as possible to the edge 14b of the finger 14 referred to by the designation MPS. Thus, when the finger 14 is slipped out of the fabric loop, a plurality of straight pins are inserted on the marks as well as through both layers of material.
2. Pinning through both layers of material at locations as close as possible to the edge 14b of the finger 14.
3. Stapling by means of a long throw stapler, preferably having an adjustable throat. This particular arrangement is shown in FIG. 7.
Upon using one of the above three methods the first or center pleat loop is established and the holding pin 15 shown in FIG. 2 can be removed.
Referring to FIG. 3, the next step in the present method is to slip the adjustable finger 16 into the first or center loop C, with the center C being positioned along the finger edge 16b, and the top single layer of material being drawn to the left. Thereafter, the procedure is to position and form pleat loops to the left of the center loop C. In order to accomplish this, the single layer of material is pulled to the left and under the marking finger 14, over and around fixed broad finger 12 and edge 12a, and to the right under finger 14 toward the adjustable broad finger 16. When this is achieved the holding pin 15 is inserted through both layers of material about 11/2 inches to the right of finger 14, as seen in FIG. 3. As described above, the operator has the option of positioning and forming the second pleat loop by either marking, pinning or stapling, as was performed in the formation of first or center loop C. The foregoing process is repeated until all the pleat loops to the left of the center are completed.
In order to position and form the pleat loops to the right of the center loop the pleat loop spacer 10 is turned over and the adjustable broad finger 16 now appears on the left. The finger 16 is inserted into the center loop with the material center C now positioned along the left edge 16b of finger 16. The material is pulled in a firm manner to the right under marking finger 14, over and around the fixed broad finger 12 and edge 12a, and thereafter to the left under finger 14 toward finger 16. Then a holding pin 15 is inserted about 11/2 inches to the left of the marking finger 14 through both layers of material. Furthermore, in order to finish the position and formation of the first pleat to the right of the center loop a selection can be made from the three methods of positioning and formation, as set forth above. Furthermore, the remainder of the pleat loops to the right of the center loop can be completed by following the procedure explained in detail hereinabove.
Referring to FIGS. 4-6 of the drawings, the pleat former 30 is shown forming a pinch pleat in the loop 40.
The pinch pleat former 30 is arrow-shaped and comprises three working edges 32, 34, and 36. It will be noted that the working edges 32 and 34 are identical in size and shape, while the other working surface 36 is positioned perpendicular to the working surfaces 32 and 34 respectively and is equi-distant from the edges 32 and 34. It will also be noted that the working edge 36 has a sloping front portion 36a.
In order to form a pinch pleat in a loop such as loop 40 of FIG. 5, the pleat loop former 30 is inserted within the loop 40 as shown in FIG. 5 with its flat base and edges 32 and 34 spreading the loop directly over the seam thereof, as seen in FIG. 6. Meanwhile, the sloping front portion 36a of the edge 36 easily slips into the loop and permits the loop former to enter the loop and to be positioned properly. Thereafter, the operator presses firmly along the raised sides of the edge 36, as shown in FIG. 6, while retaining a releasable hold on the raised center portion of the material and gently withdrawing the pleat former 30. Thereafter, both side folds are brought up to form the pinch pleat which is precisely formed.
It will be seen from FIG. 7 that the pleat loop spacer can be constituted of only two fingers on a base member. One of the fingers 12 is fixed while the other finger 16 is adjustable in a manner described hereinbefore. The pleat loops are formed as described hereinbefore, however a stapler 24 with a long throat which is precisely dimensioned is utilized. It is also within the spirit and scope of the present invention to make the throat of the stapler adjustable, however the stapler is so designed that it will staple the fabric at the precise location with the edge 12a serving as a guide or stop for the throat interior end. In this manner, precisely reproducible pleats can be formed rapidly and accurately, and it should be apparent that this can be done by unskilled workers as well as by professionals.
It should be observed that the present device overcomes the complexity of prior known devices and permits any person desiring to make drapes to quickly and accurately position pinch pleats in a drapery material of diverse widths. Moreover, the portable drapery pleat loop spacer may be fabricated out of plastic, metal or hard board stampings, and as such, can be economically manufactured.
FIGS. 8-13 show an alternate embodiment of the present invention. It will be seen that the fabric pleater guide 38 is provided with a fixed finger 40, a finger 42 that is either adjustable or fixed, and an adjustable finger 44. The guide 38 is in the form of a straight edge having ruler markings, and as seen in FIGS. 11-13, is placed on the drapery panel on the wrong or opposite side thereof, for measuring the pleat locations. It should be pointed out that drapery headings currently being used employ stiffeners which make it very difficult, if not impossible, to repeatedly insert straight pins through the double thicknesses of the material. In order to avoid this serious problem, the present simplified device has been developed. The fabric material for the drapery panel is laid stationary and flat on a flat surface which may be a floor or a table, etc., and does not have to be folded or otherwise handled by the sewing operator while positioning the pleats. Furthermore, the panel can be initially completely finished, and the pleats positioned thereafter from either the left or the right side thereof.
Referring now more particularly to FIGS. 11-13, showing the actional mode of operation of the device, it should be noted that in preparing a drapery panel for the selected dimensions for a specific drapery rod size, the panel may be completely finished with side hems before positioning the pleats, return and lap. The prepared panel is then laid on a flat surface with the reverse or wrong side up, as seen in FIG. 11, and along the top edge of the heading a measurement is made from the left side of the prepared panel which is the distance required for the lap or the return. A pin P1 is inserted in the top edge of the heading marking this location. If the side hems have not been completed, then one half of the five inch allowance for the side hems must be added to the measurement before pin 1 is inserted. The fabric pleater guide is then positioned on the drapery panel with the fixed finger 40 directly under pin P1. With the guide in this position, a pin P2 is inserted in the top edge of the heading directly above the finger 42. This latter pin indicates the center of the first pleat loop.
The guide 38 is then moved to the right until the finger 40 is directly under the pin P2 which thus identifies the center of the first pleat loop. While maintaining the fabric pleater guide in the latter position a pin P3 is inserted in the top edge of the heading directly above the movable finger 44. Pin 3 then marks the center of the pleat 2. The above procedure is repeated until the centers of the required number of pleat loops for the panel are marked with pins along the top edge of the panel heading. The designation of the pleat loops is completed by positioning the fabric pleater guide with the fixed finger 40 under the pin P7 marking the center of the last pleat loop. It will be noted that the pin P8 is directly above the finger 42. The remaining material to the right of pin P8 conforms to the measurement of the lap or the return, plus the hem allowance, if not already finished.
In order to complete the pleat loop, the material is folded at right angles to the top edge of the fabric panel heading with the pin marking the center of the fold. The material is then sewed in order to finish the loop with the use of a former 30 shown in FIGS. 4-6 utilized in a manner described hereinbefore.
It will be observed that the fabric pleater guide set forth hereinabove is simple in construction, as well as easy to use by both experienced and inexperienced sewing operators. | A simplified adjustable fabric pleater guide particularly for use in spacing and forming pinch pleats in draperies. A scale is provided on a measuring stick which may be metrically calibrated, as well as calibrated in inches, while an index is provided on the adjustable fabric guide for rapidly and accurately setting the required primer pleats longitudinally on the fabric. A pinch pleat former is utilized to quickly and accurately divide the primary pleats into pinch pleats. | 3 |
BACKGROUND OF THE INVENTION
1. Technical Field
The present invention relates to a system, method, and pointing device for remote operation of data processing apparatus.
2. Description of the Prior Art
In recent years, there has been explosive growth in the Internet, and in particular of the WorldWide Web (WWW), which is one of the facilities provided via the Internet. The WWW comprises many pages or files of information, distributed across many different servers. Each page is identified by an individual address or "Universal Resource Locator (URL)". Each URL denotes both a server machine, and a particular file or page on that machine. There may be many pages or URLs resident on a single server.
Typically, to utilise the WWW, a user runs a computer program called a Web browser on a client computer system such as a personal computer. Examples of widely available Web browsers include the "WebExplorer" Web browser provided by International Business Machines Corporation in the OS/2 Operating System software, or the "Navigator" Web browser available from Netscape Communications Corporation. The user interacts with the Web browser to select a particular URL. The interaction causes the browser to send a request for the page or file identified in selected URL to the server identified in the selected URL. Typically, the server responds to the request by retrieving the requested page, and transmitting the data for that page back to the requesting client. The client-server interaction is usually performed in accordance with a protocol called the hypertext transfer protocol ("http"). The page received by the client is then displayed to the user on a display screen of the client. The client may also cause the server to launch an application, for example to search for WWW pages relating to particular topics.
WWW pages are typically formatted in accordance with a computer programming language known as hypertext mark-up language ("html"). Thus a typical WWW page includes text together with embedded formatting commands, referred to as tags, that can be employed to control for example font style, font size, lay-out etc. The Web browser parses the HTML script in order to display the text in accordance with the specified format. In addition, an html page also contain a reference, in terms of another URL, to a portion of multimedia data such as an image, video segment, or audio file. The Web Browser responds to such a reference by retrieving and displaying or playing the multimedia data. Alternatively, the multimedia data may reside on its own WWW page, without surrounding html text.
Most WWW pages also contain one or more references to other WWW pages, which need not reside on the same server as the original page. Such references may be activated by the user selecting particular locations on the screen, typically by clicking a mouse control button. These references or locations are known as hyperlinks, and are typically flagged by the Web browser in a particular manner. For example, any text associated with a hyperlink may be displayed in a different colour. If a user selects the hyperlinked text, then the referenced page is retrieved and replaces the currently displayed page.
Further information about html and the WWW can be found in "World Wide Web and HTML" by Douglas McArthur, p18-26 in Dr Dobbs Journal, December 1994, and in "The HTML SourceBook" by Ian Graham, John Wiley, New York, 1995.
Conventionally, to access WWW pages via the Internet, a user has needed access to relatively specialised and expensive hardware such a personal computer fitted with a modem communications link and a WWW browser software package. More recently, there have become available a variety of so-called "set-top boxes" each for linking a domestic television receiver to the WWW. Examples of such step top boxes includes the Internet TV Terminal available from Phillips/Magnavox and the WebTV Internet Terminal available from Sony Corporation. A set-top box typically includes a modem communication link connectable to the WWW via a subscriber telephone line and a video output connectable to a domestic television receiver for displaying WWW pages down-loaded from the WWW via the modem link. It would be desirable to enable users to access the Internet access with no, or at most the bare minimum of, additional specialist hardware. It would also be desirable to provide a simple user interface for controlling computer applications delivered to a user via a television receiver. U.S Pat. No. 5,236,199 describes an interactive media system and tele-computing method in which a Discrete Tone, Multiple Frequency (DTMF) key-pad of a domestic telephone is employed as a pointing device for moving a cursor on, and selecting options from, the screen of a domestic television receiver. It would be desirable however to provide a pointing device which is simpler to use for such applications.
SUMMARY OF THE INVENTION
In accordance with the present invention, there is now provided a pointing device comprising: a sensor for directing towards an icon displayed on a display screen, the sensor generating a sense signal indicative of an attribute of the icon; and an audio generator for generating, in dependence on the sense signal, an audio signal for subsequent detection by the microphone of a telephone.
This advantageously provides a pointing device for selecting options displayed on a television screen simply by pointing the device at the or each desired option.
The sensor may generate the sense signal as a function of the shape of the icon. Alternatively, the sensor may generate the sense signal as a function of the colour of the icon.
In preferred embodiments of the present invention, a light source is provided for generating a light beam to produce a targeting spot on the display screen to assist aiming of the pointing device.
Viewing the present invention from another aspect, there is provided a system for remote selection of one or more options in a data processing apparatus the system comprising: means for receiving a call from a telephone; means for allocating a teletext page in a television signal in response to the call; means for associating the or each option with an icon; means for writing the or each icon to the allocated teletext page; means for associating the or each icon with an audio signal; and, means for activating the or each option on receipt of the corresponding audio signal from the telephone.
The system preferably comprises means for sending a message identifying the allocated teletext page to the telephone.
The data processing apparatus may comprise a computer network, in which case the system may comprise means for generating a menu of data files available via the computer network, each data file having a different icon specified in the menu, means for writing the menu to the allocated teletext page; means for receiving the audio signal corresponding to a selected icon from the telephone; and means for writing data from the data file corresponding to the selected icon to the allocated teletext page. The system may further comprise means for generating successive menus of data files in response to successive selections received via the telephone.
Preferably, the system comprises means for releasing the allocated teletext page for re-allocation in response to termination of the telephone call.
The system may comprise means for detecting if a teletext page is available for allocation to an incoming call and, in the event that no teletext pages are available for allocation, for returning the incoming call when a teletext page is released for re-allocation.
It will be appreciated that the system may comprise a pointing device as hereinbefore described.
Viewing the present invention from yet another aspect, there is provided a method for selecting an icon on a display screen, comprising: generating, via a sensor directed towards the icon, a sense signal indicative of an attribute of the icon; and generating, in dependence on the sense signal, an audio signal for subsequent detection by the microphone of a telephone.
Viewing the present invention from a further aspect, there is provided a method for remote selection of one or more options in a data processing apparatus, the method comprising: receiving a call from a telephone; allocating a teletext page in a television signal in response to the call; associating the or each option with an icon; writing the or each icon to the allocated teletext page; associating the or each icon with an audio signal; and, activating the or each option on receipt of the corresponding audio signal from the telephone.
BRIEF DESCRIPTION OF THE DRAWINGS
Preferred embodiments of the present invention will now be described by way of example only with reference to the accompanying drawings, in which:
FIG. 1 is a block diagram of a data communications network;
FIG. 2 is a block diagram of a server computer of the data communications network;
FIG. 3 is a block diagram of a teletext server of the data communications network;
FIG. 4 is a block diagram of a pointing device for controlling access to the data communication network; and,
FIG. 5 is another block diagram of the teletext server presented in the form of a flow chart.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring first to FIG. 1, a data communication network embodying the present invention comprises the Internet 100. A plurality of WWW server computer systems 110-130 are connected to Internet 100. Also connected to Internet 140 is a teletext server 140. Teletext server 120 is configured to receive an input from Discrete Tone Multiple Frequency (DTMF) subscriber telephone 170. Teletext server 120 also provides a teletext output to a broadcast television receiver 150 capable of receiving teletext pages. Television receiver 150 can be instructed by user 180 to access different teletext pages via a remote control device 160.
Referring now to FIG. 2, each WWW server 110-130 includes a keyboard 200 attached to a system unit 210 including a main CPU 220, system RAM 230, system ROM 240, and mass storage capability 250, typically in the form of multiple magnetic disk drives constituted in a RAID (redundant array of independent disks) arrangement. Each WWW server 110-130 has stored in its mass storage 250 at least one WWW page. Each WWW server 110-130 also includes a display 260 enabling direct interaction between the WWW server 110-130 and an administrator. Each WWW server 110-130 may also include other storage devices such as diskette drives and CD ROM drives. In some embodiments of the present invention, the display 260 and keyboard 200 of each WWW server 110-130 provided via an intermediate personal computer.
Referring now to FIG. 3, teletext server 140 comprises a telephone call handler 300, a web browser 310, and a WWW page convertor 320 all interconnected to each other. In some embodiments of the present invention, telephone handler 300, web browser 310, and WWW page convertor 320 may be integrated into a single server computer system on the kind hereinbefore described with reference to FIG. 2. However, in other embodiments of the present invention, teletext server 140 may comprise separate computer systems for implementing each of call handler 300, web browser 310, and page convertor 320. Call handler receives incoming telephones calls made to one or more pre-assigned telephone numbers. The pre-assigned telephone numbers may, for example, be premium rate telephone numbers. Web browser 310 is connected to the Internet for accessing WWW pages. WWW page convertor 320 is connected to a teletext input of a broadcast television signal generator (not shown).
Referring now to FIG. 4, an example of a pointing device 500 embodying the present invention comprises a light source 560 for generating a light beam 565 to produce a light spot on the screen of television receiver 150. The light spot enable the user to aim the pointing device at an icon 505 displayed on the screen of television receiver 150. Light source 560 may comprise, for example a low power laser. Pointing device 500 further comprises a sensor 510 for generating an output on detection of icon 505. The output of sensor 510 is connected to the input of a tone generator 520. The output of tone generator 520 is connected to a loudspeaker 530. In operation, sensor 510 generates an electrical signal representative of one or more attributes, such as shape and colour of the icon at which pointing device is generated. In a particularly preferred embodiment of the present invention which serves as the basis of the following description, sensor 510 comprises a shape sensitive transducer such a charge coupled (CCD) device for generating an electrical output signal representative of the shape of the icon 505 at which pointing device 500 is directed. Tone generator generates an AC electrical signal of a frequency determined by the output from sensor 510. It will appreciated from FIG. 4 that tone generator 520 may for example comprise an analog to digital convertor (ADC) 540 for digitising the output from sensor 510 and a tone selector 550 for selecting the output signal frequency in accordance with the digitised sensor output. Loudspeaker 530 generates an audio tone in response to the AC signal output from tone generator 550. The audio tone produced by speaker 530 of pointing device 500 is detected by a microphone 175 of telephone 170 and sent to server 140 via the telephone network 145. In some embodiments of the present invention, for use in conjunction with hands-free telephone equipment for example, pointing device may be provided in a single hand-held unit. However, in other embodiments of the present invention, pointing device 500 may be divided into two or more separate units with sensor 510 and light source 540 located in a hand-held portion and speaker 530 located in a portion for attachment to, or positioning within the range of sensitivity of, a telephone hand-set.
Referring now to FIG. 5, to display information from a WWW page on television receiver 150, user 180 places a telephone call from telephone 170 to a telephone number associated with call handler 300 of teletext server 140 as signified by input block 400. At block 410, call handler 300 responds to the incoming call by allocating a currently unused teletext page to the user. Call handler 300 automatically generates an audio message for indicating the number of the allocated teletext page to the user.
Web browser 310 provides an initial subject menu to page convertor 310. At block 420, page convertor 320 inserts the initial subject menu into the allocated teletext page. The teletext page including the menu is inserted in the broadcast television signal. The teletext page is recovered from broadcast television signal at television receiver 150, and the subject menu is displayed on the screen of television receiver 150. User 180 accesses the allocated teletext page and hence the subject menu by keying the number supplied via telephone 170 on remote control device 160. Television receiver displays the allocated teletext page in response to the corresponding output of remote control device 160. Each item on the subject menu is associated with a different shaped icon 505.
User 180 selects, at block 430, a particular item from the subject menu by directing pointing device 500 towards the corresponding icon 505 and enabling pointing device to generate the corresponding audio tone, by depressing an enable button of pointing device 500 for example. The corresponding audio tone is detected by microphone 175 of telephone 170. Call handler 300 detects the audio tone received by telephone 170; identifies the icon signified by the audio tone; and passes the icon identified to web browser 310. At block 450, a search engine of web browser 310 scans internet 100 for WW pages corresponding to the subject selected by the user. Web browser 310 then generates a WWW menu of WWW pages identified by the search engine. Each WWW page listed in the WWW menu is accompanied by a brief description of the content thereof, and each WWW page listed in the WWW menu is, once again associated with a different shaped icon. Web browser 310 compiles a look up table mapping each icon to the URL of the corresponding WWW page. The WWW menu is passed by web browser 310 to page convertor 320 for inclusion in the teletext page allocated to user 180.
If user 180 fails to make a selection from the initial menu during a predetermined time out period monitored at block 440 then, at block 460, the telephone call connection between telephone 170 and call handler 300 is terminated by call handler 300. At block 520, call handler 300 releases the allocated teletext page for re-allocation to a new user. If however selection from the initial menu is made as hereinbefore described, user 180 is presented with the WWW menu on the screen of television receiver 150. At block 470, user selects a WWW page of interest from WWW menu by directed pointing device 500 at the corresponding icon so that pointing device generates the corresponding audio tone which, in turn, is detected by telephone 170 and returned to server 140. Call handler 300 detects the audio tone, recovers the corresponding icon, and sends the recovered icon to web browser 310. Web browser 310 then retrieves the URL corresponding to the icon from the look up table and the WWW page corresponding to the URL from Internet 100. The retrieved www page is sent by web browser 310 to page convertor 320. At block 490, page convertor 320 converts the WWW page supplied by web browser to a form suitable for inclusion in the allocated teletext page and updates the allocates the teletext page to include the converted WWW page for presentation to user 180 on the screen of television receiver 150.
If user 180 fails to select a WwW page within a predetermined time out period then, at block 480, user 180 is returned to the initial menu for subject selection at block 430.
Each hypertext link contained in the retrieved WWW page, if any, is converted by page convertor 320 into an icon for inclusion in the allocated teletext page. Page convertor 320 instructs web browser to update the look-up table to include the icon corresponding to each hypertext link. At block 500, user 180 can select the hypertext link by directing pointing device at the corresponding icon so that the corresponding audio tone is detected by telephone 170. The audio tone is detected by call handler 300 and the corresponding icon is determined and sent to web browser 310. In turn, web browser 310 retrieves the URL corresponding to the icon from the look-up table and retrieves the corresponding linked WWW page from Internet 100. The linked WWW page retrieved by web browser 310 is converted to teletext format by page convertor 320 and included in the allocated teletext page for display to user 180.
At block 510, user 180 can terminate the Internet session simply by terminating the call set up between telephone 170 and call handler 300. As mentioned earlier, on detection of termination of the call, at block 520 call handler releases the allocated teletext page for re-allocation to a new user.
In the embodiment of the present invention hereinbefore described two tiers of menus are provided, with possible selections reverting to those of the initial menu in the event that no selection is made from the WWW menu within a predetermined time interval. It will however appreciated that, in other embodiments of the present invention, more than two tiers of menus may be provided with possible selections reverting to those of earlier menus in the event of no selection within a predetermined period. Equally, in some embodiments of the present invention, only a single menu of available WKW pages may provided.
In a modification of the embodiment of the present invention hereinbefore described, call handler 300 may include a facsimile sub-system for providing a user having access to a facsimile receiver with a printed output of a selected WWW page.
In another modification of the embodiment of the present invention hereinbefore described, call handler 300 may include a "call-back on busy" sub-system for returning a call to telephone 170 when a teletext page is free for allocation in the event of an initial call from telephone 170 being made at a time when all teletext pages available to server 140 are already allocated to other users.
In particularly preferred embodiments of the present invention, at least one of the teletext pages available to server 130 is reserved by call handler 300 for providing on-screen help to user 180.
In the preferred embodiments of the present invention hereinbefore described, sensor 510 of pointing device 500 generates an output signal representative of the shape of the icon to which pointing device 500 is directed. It will be appreciated that, in other embodiments of the present invention sensor 510 may be sensitive to one or more different attributes of an icon. Such sensors may be based on one or more of a plurality of different types of transducer. Selection of transducer or combination of transducers is dependent on the attribute or combination of attributes of icon 510 to which sensor 510 is to be made sensitive. For example, in some preferred embodiments of the present invention, sensor 510 may comprise a wavelength sensitive transducer for generating an output signal dependent on the colour of the icon.
Although preferred embodiments of the present invention have been hereinbefore described with reference to a system for providing internet access via a domestic television receiver, it will be appreciated that the present invention is not limited to such an application and may equally be employed to provide pointing device capability in other remote computing applications.
In the preferred embodiments of the present invention hereinbefore described, pointing device 500 is provided with a light source 560 for generating a targeting spot on the television screen. It will be appreciated that, in other embodiments of the present invention, light source 560 may be omitted. For example, in another embodiments of the present invention, the portion of pointing device 500 carrying sensor 510 may be adapted for positioning against the screen of television receiver 150 to adjacent the displayed corresponding to the desired option. | A pointing device having a sensor for directing towards an icon displayed on a display screen. The sensor generates a sense signal indicative of an attribute of the icon. An audio generator generates, in dependence on the sense signal, an audio signal for subsequent detection by the microphone of a telephone. Also, a system includes the pointing device, for remote selection of one or more options in a data processing apparatus. The system is capable of receiving a call from a telephone; allocating a teletext page in a television signal in response to the call; associating each option with an icon; writing each icon to the allocated teletext page; associating each icon with an audio signal; and, activating each option on receipt of the corresponding audio signal from the telephone. | 7 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority from U.S. Provisional Patent No. 61/374,538 entitled “System and Method for Managing Information Technology Infrastructure” that was filed on Aug. 17, 2010.
FIELD OF THE INVENTION
The invention relates generally to a system for managing information technology infrastructure.
BACKGROUND ART
Over the past years, information technology (IT) systems for business and other similar organizations have become very fractured. The IT systems are typically inter-related but not inter-dependent. For example, a trunk port had to work on the PBX for the router to work but the phone system would work whether their network security was up or not. The surveillance camera system operated on a separate coaxial cabling system and was completely independent of IT system. E-mail didn't depend on the phone system working and conversely the voice messages didn't depend on their e-mail working. Thus, it is still common to think in “stovepipe” terms even though the technology has become converged.
Many businesses, because of the historical nature of a widely fractured network infrastructure topology, still view IT from a historical perspective. For example, many organize their IT department—Director, Telecommunications; Director—Network Administration; Manager—Network Security; Server Manager; Desktop Support Services, etc. This tells you that their IT infrastructure is viewed from a historical, fragmented perspective. Companies experience “turf wars” because each department does not have in-depth understanding of how their components interface and affect other departmental components. Compound this much fractured structure with each of these departments depending on multiple IT “stovepipe” vendors and one can quickly see why IT infrastructure has become so frustrating.
In actuality, providing the ability for devices to have digital communications—whether it is to a camera, a phone, a desktop, laptop, PDA, digital sign, or any other end user device, is now quickly advancing towards a converged network and all devices (as well evidenced by phones, signage, cameras, etc.) are just becoming another end-user device powered by an IP address. However, many organizations are realizing that this type of organizational structure flies in the face of the converged network. Consequently, this connectivity must be delivered by a system reliably, quickly, and securely.
SUMMARY OF THE INVENTION
In some aspects, the invention relates to a system for developing and managing information technology infrastructure management and operations (IMO), comprising: establishing a remote system help desk to clear IMO problems based on severity; establishing a remote network operations center (NOC) to monitor system equipment and provide IMO incident management and remediation; establishing a staging center to perform setup, configuration and testing of system upgrades and new equipment installations; and generating a IMO report for system status and performance for storage in an electronic media.
In other aspects, the invention relates to a system for developing and managing information technology infrastructure management and operations (IMO), comprising: step for establishing a remote system help desk to clear system problems based on severity classification; step for establishing a remote network operations center (NOC) to monitor system equipment and provide equipment problem remediation; step for establishing a staging center to perform setup, configuration and testing of system upgrades and new system installations; and step generating and storing a IMO report for system status and performance for in an electronic media.
Other aspects and advantages of the invention will be apparent from the following description and the appended claims.
BRIEF DESCRIPTION OF DRAWINGS
It should be noted that identical features in different drawings are shown with the same reference numeral.
FIG. 1 shows a IMO process decision tree chart for service calls in accordance with one embodiment of the present invention.
FIG. 2 shows a listed of service call classifications and performance standards in accordance with one embodiment of the present invention.
DETAILED DESCRIPTION
The present invention is a system and method for designing, managing and operating IT infrastructure for an organization. In some embodiments, the invention develops an Infrastructure Management and Operations (IMO) plan that optimizes an organization's IT infrastructure. The IMO allows the organization to outsource to third party assets to dramatically improve their operations by using:
A third party Help Desk (Tiers 1 through 3) remotely clears problems and thus lowers IT problem resolution times; A third party NOC (Network Operations Center) that monitors equipment, allows incident management and provides remote remediation. Perhaps more importantly, it provides predictive, pro-active monitoring which can predict and eliminate problems before they occur and affect the organization's operations; A third party Staging Center and Lab that performs pre-staging, burn-in, and configuration testing and verification so that new applications or upgrades to applications do not adversely affect the organization's production systems; Specialized technical personnel (the ATG) that allows the organization's operations to incur less downtime in IT infrastructure, eliminates “finger pointing” between multiple vendors and manufacturers, and resolves IT problems much more quickly. Additionally, specialists who understand particular areas of IT infrastructure, while understanding how their related area relates to the network as a whole, can significantly improve network up-time and resolve problems in a fraction of the time that organizations experience when providing their own (and fractured vendor) support; and Finally, through generated reports, organizations can much better gauge their IT effectiveness and efficiencies.
FIG. 1 decision tree chart for service calls for a fully developed IMO plan in example of the present invention. FIG. 2 shows an example of service call classifications and performance standards in accordance with the IMO plan of FIG. 1 .
In a preferred embodiment, the present invention is directed towards an organization with 100 to 2,000 employees. Organizations within this size range have many of the same sophisticated IT needs as larger organizations yet have even less ability to scale. Organizations, smaller than this range, may not need very sophisticated IT services and can be served by retail-like IT entities. Larger organizations may feel that they are big enough to provide their own scale. However, it should be understood that the present invention could be applied to organizations outside this size range as well.
In order to deliver true value to an organization over time, the IMO development process must intimately understand its business objectives, its values and its culture. As a part of this, the IMO development process must also understand the organization's IT infrastructure architecture and operations and the business application functionality it is intended to deliver. The reality of a converged enterprise IP network backbone populated by many discreet, yet interdependent elements, requires a holistic view as well.
The IMO development process acquires knowledge of an organization's IT system during an assessment phase. The assessment phase is ideally conducted in a non-disruptive manner to the organization's normal operations. The goal of the assessment is to gain an understanding of the interfaces, the interactions and interdependencies of the multiple devices, usually from multiple manufacturers, on the IT network. It is completely focused on how to optimize the design, management and operation of that heterogeneous network including: initial conceptual architectural design; predictive NOC monitoring; routine help desk and field support; high-level, specialized expertise; and objectively and quantitatively measuring the end user satisfaction. During the assessment phase, the IMO process: gathers the basic information about the organization's logical architectural design and its current infrastructure; analyzes the organization's operational support systems, processes and policies and future plans; meets the organization's leadership and observes the business environment first hand and gains insight into the organization's culture and values; and develops a specific scope of work (SOW) and a cost model to propose the framework for a detailed, customized long term IMO plan.
Prior to beginning the assessment phase, the following should be clearly identified about the organization: (a) what does it do? (b) how many locations do it have? (c) how many employees does it have? (d) what are its annual sales? (e) Is it profitable or losing money? (f) What are its biggest challenges from a business perspective? and (g) What are its largest challenges from an IT perspective? (h) What seems to be the biggest “pain point” regarding IT? (i) How many IT employees does it have? (j) How many maintenance contracts do they have? (k) Does it use a lot of outside resources? (l) Who is its carrier? (m) How well is the IT managed? (n) What level of sophistication do they have? (o) Do they get any type of reports, and, if so, are they available? (p) Does the prospect utilize any type of Helpdesk or NOC services? (q) Are these capabilities provided from an “in house” solution or do they use a vendor? and (r) Do they utilize co-location facilities?
Additionally, the following information is typically gathered during the assessment phase: Estimated number of service tickets or problems; Existing maintenance requirements; Amount of outside vendor support; Personnel and their roles and responsibilities; Types of systems and numbers of devices; Who and which of the organization's team members are responsible for what equipment; How much time should be taken in its assessment process; and Limits of the potential scope the assessment phase.
As a general rule, the more information, relevant to the IT infrastructure obtained, the better. A specific check list or group of reports are not provided for the assessment phase because every organization is unique. Therefore, this list will vary greatly in different applications. The ultimate goal of the assessment phase is identify and understand the organization's: (a) cable infrastructure position; (b) server capabilities; (c) network security condition; (d) wireless situation; (e) ability to operate on a VOIP platform; (f) monitoring needs; (g) specific reports that need to better management and measurement of IT performance; (h) video-conferencing, IP security, and digital signage requirements (or the ability to add them if desired); (i) IP addressing schemes; (j) routing and switching capacities; (k) exactly how a help desk should be integrated into the processes; and (l) assessing staff and vendors and recognizing how they should be transitioned into the IMO model. It should be understood that other features of the organization could be recognized during the assessment phase that will impact the IMO process.
In summary, the Assessment phase is a powerful and central point of success with an IMO process. It gathers the information and understanding and generates the SOW and Cost Model. There are many details as exactly how and when things are laid out that are left to the transition phase. After the SOW is executed, a transition phase will map out a specific project plan and incorporate the hundreds of detailed steps to evolve the organization from its current state to the future state and then to ongoing business as usual operations.
The entire advantage of the IMO process of the present invention is relatively simple. It helps mid-sized companies meet their IT needs at a competitive cost with a dramatic positive results in the core operations. More specifically, the present invention has the following advantages: Using a single vendor and avoiding the “finger pointing” syndrome when attempting to get problems resolved with several vendors; Confidence with the security of the entire network; Avoiding augmentation of in-house IT staff by outside resources in order to achieve their IT objective; IT projects brought in consistently on time and on budget; Ease of handling remote location support; Cost effective IT field support resources; Pro-actively determining problems before they occur; Resolving a high percentage of IT problems remotely; Ability to handle technology issues that fall outside in-house IT staff's competency range; Ability to handle problems when in-house IT staff members are out due to sickness, vacation, or training; Selecting hardware that properly supports the application software; and Synchronizing all IT/Voice maintenance contracts to be coterminous and match the budget cycle.
While the invention has been described with respect to a limited number of embodiments, those skilled in the art, having benefit of this disclosure, will appreciate that other embodiments can be devised which do not depart from the scope of the invention as disclosed here. Accordingly, the scope of the invention should be limited only by the attached claims. | A system for developing and managing information technology infrastructure management and operations has been developed. The system includes establishing a remote system help desk to clear IMO problems based on severity. Also, a remote network operations center (NOC) is established to monitor system equipment and provide IMO incident management and remediation. Additionally, a staging center is established to perform setup, configuration and testing of system upgrades and new equipment installations. Finally, a report for system status and performance for storage in an electronic media is generated. | 6 |
RELATED APPLICATION
This application claims priority from U.S. patent application Ser. No. 09/752,428.
FIELD OF THE INVENTION
The present invention relates to warm/cold double-circulation water filter system and swimming pool arrangement and more particularly to a pipe controlling means.
BACKGROUND OF THE INVENTION
For background, reference is made to U.S. patent application Ser. No. 09/752,428, now U.S. Pat. No. 6,425,999 which describes a double-circulation water filter system and swimming pool arrangement. The swimming pool is separated into two pools for enabling warm/cold water to be respectively circulated through the pools of the swimming pol via a divided water filter unit and enables warm/cold water to be selectively circulated through the two pools of the swimming pool. The water pipe system 4 is between a swimming pool 1 and a double-circulation water filter system 3 . (refer to FIG. 4 of originally filed application). The swimming pool 1 is separated into two separated pools, a first pool 12 and a second pool 14 . Each of the pools 12 and 14 has a water outlet 122 or 142 , and a plurality of water inlets 124 or 144 . The water pipe system 4 connects the water inlets 122 and 142 of the pools 12 and 14 to the water inlets 124 and 144 through the double-circulation water filter system 3 . Electromagnetic valves A, B, C, D, E and F are installed in the water pipe system 4 , and are adapted to control the direction of water flow. The inconvenient control and management of the valves that are dispersed along the water pipe system 4 , raise an issue to be resolved.
SUMMARY OF THE INVENTION
It is an objective of the invention to provide a warm/cold double-circulation water filter system and swimming pool arrangement which concentrated on the valves in order to convenient management and control.
It is another objective of the invention to provide a warm/cold double-circulation water filter system and swimming pool arrangement which reduce the amount of the valves.
It is another objective of the invention to provide a warm/cold double-circulation water filter system and swimming pool arrangement which supply a multiform elevated temperature manner.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates the arrangement of the double-circulation water filter system and the water pipe system according to the present invention.
FIG. 2 illustrates the arrangement of elevated temperature device of a single swimming pool according to the present invention.
FIG. 3 illustrates the arrangement of elevated temperature device of a single swimming pool according to the present invention.
FIG. 4 illustrates the arrangement of elevated temperature device of the double swimming pool according to the present invention.
FIG. 5 illustrates the arrangement of the double cold water swimming pool according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, the present invention comprises a swimming pool 1 , a partition wall 20 , a double-circulation water filter system 3 and a water pipe system 4 . The present invention more particularly concerns the water pipe system 4 having a pipe controlling means 60 which is connected to a heater 50 by a pipe. Said pipe controlling means includes a first water inlet pipe 61 , a second water inlet pipe 62 , a first water outlet pipe 63 and a second water outlet pipe 64 . The first water outlet pipe 61 is connected to the water outlet 122 of the pool 12 through a hair remover 48 , a filter tank 42 , a chlorinator 44 and a chemical dispenser 46 . The first water inlet pipe 61 and the first water outlet pipe 63 , connected to the water inlet 124 of said pool 12 , complete the connection of the water filter system to the pool 12 . The second water inlet pipe 62 is connected to the water outlet 142 of said pool 14 through a hair remover 38 , a filter tank 32 , a chlorinator 34 and a chemical dispenser 36 . The second water inlet pipe 62 and the second water outlet pipe 64 , connected to the water inlet 144 of said pool 14 , complete the connection of the water filter system to the pool 14 . The pipe controlling means 60 includes a connecting pipe 65 , is connected to the first water inlet pipe 61 , the second water inlet pipe 62 , the first water outlet pipe 63 and the second water outlet pipe 64 . The joint of the connecting pipe 65 and the first water inlet pipe 61 have a first control valve 66 . The joint of the connecting pipe 65 and the second water inlet pipe 62 have a second control valve 67 . The connecting pipe 65 has a third control valve 68 connected thereto. The first, second and third valves are each a triple valve which is used to control the direction of water flow. Furthermore, a heating pipe 69 extends between the first control valve 66 and the second control valve 67 and is connected to the hot water inlet 51 of a heater 50 . The joint of the connecting pipe 65 and the third control valve 68 have a hot water outlet pipe 71 , connected to the hot water outlet 52 of the heater 50 .
Refer to FIG. 2, the water effusion of the water outlet 122 of the pool 12 through the double-circulation water filter system 40 pass the first water inlet 61 into the pipe controlling means 60 . The water of the first water inlet pipe 61 leads through the heating pipe 69 through the heater 50 by the first control valve 66 . And, the water lead to the water inlet 124 of said pool 12 constructive heating circulation system by hot water outlet 52 , hot water outlet pipe 71 , the third control valve 68 and the first water outlet pipe 63 .
Refer to FIG. 3, the water effusion of the water outlet 142 of the pool 14 through the double-circulation water filter system 30 pass the first water inlet 62 into the pipe controlling means 60 . The water of the first water inlet pipe 62 leads into the heating pipe 69 into the heater 50 by the first control valve 67 . And, the water lead to the water inlet 144 of said pool 14 constructive heating circulation system by hot water outlet 52 , hot water outlet pipe 71 , the third control valve 68 and the first water outlet pipe 64
Refer to FIG. 4, the water effuse from the water outlet 122 , 142 of the pool 12 , 14 through the double-circulation water filter system 40 , 30 into pipe controlling means 60 by the first, second water inlet pipe 61 , 62 . The water effusion of the first, second water inlet pipe 61 , 62 leads through the heating pipe 69 into the heater 50 by the first, second control valve 66 , 67 . The hot water is divided effused into the water inlet 124 , 144 of said pool 12 , 14 by the first, second water outlet pipe 63 , 64 and constructive heating circulation system.
Refer to FIG. 5, the water effused from outlet 122 , 142 of said pool 12 , 14 through double-circulation water filter system 40 , 30 into pipe controlling means 60 by the first, second water inlet pipe 61 , 62 . The water is divided effused into the water inlet 124 , 144 of said pool 12 , 14 by the first, second water outlet pipe 63 , 64 and constructive cold water circulation filter system by the first, second control valve 66 , 67 .
It is to be understood that the drawings are designed for purposes of illustration only, and are not intended for use as a definition of the limits and scope of the invention disclosed. | A warm/cold double-circulation water filter system and swimming pool arrangement comprises, a swimming pool, a double-circulation water filter system, a water pipe system, a heater. The present invention concentrated the valves in order to convenient management and control, to reduce valves amount and to offer a multiform elevated temperature manner. | 4 |
[0001] This application is a continuation and claims priority to U.S. application Ser. No. 11/677,502, filed Feb. 21, 2007, now U.S. Pat. No. 7,579,141, which is a divisional of, and claims priority to, U.S. application Ser. No. 10/009,383, filed Mar. 4, 2002, which claims priority to International Application No. PCT/US00/12257, filed May 4, 2000, which claims priority to U.S. Provisional Application Ser. No. 60/132,505, filed May 4, 1999, the disclosures of each of which are hereby incorporated by reference in their entireties.
BACKGROUND OF THE INVENTION
[0002] Tuberculosis infection continues to be a world-wide health problem. This situation has recently been greatly exacerbated by the emergence of multi-drug resistant strains of M. tuberculosis and the international AIDS epidemic. It has thus become increasingly important that effective vaccines against and reliable diagnostic reagents for M. tuberculosis be produced.
[0003] The disclosure of U.S. Pat. No. 6,087,163 is incorporated herein by reference in its entirety.
SUMMARY OF THE INVENTION
[0004] The invention is based on the inventor's discovery that a polypeptide encoded by an open reading frame (ORF) in the genome of M. tuberculosis that is absent from the genome of the Bacille Calmette Guerin (BCG) strain of M. bovis elicited a delayed-type hypersensitivity response in animals infected with M. tuberculosis but not in animals sensitized with BCG. Thus proteins encoded by ORFs present in the genome of M. tuberculosis but absent from the genome of BCG represent reagents that are useful in discriminating between M. tuberculosis and BCG and, in particular, for diagnostic methods (e.g., skin tests and in vitro assays for M. tuberculosis -specific antibodies and lymphocyte responsiveness) which discriminate between exposure of a subject to M. tuberculosis and vaccination with BCG. The invention features these polypeptides, functional segments thereof, DNA molecules encoding either the polypeptides or the functional segments, vectors containing the DNA molecules, cells transformed by the vectors, compositions containing one or more of any of the above polypeptides, functional segments, or DNA molecules, and a variety of diagnostic, therapeutic, and prophylactic (vaccine) methodologies utilizing the foregoing.
[0005] Specifically, the invention features an isolated DNA molecule containing a DNA sequence encoding a polypeptide with a first amino acid sequence that can be the amino acid sequence of the polypeptide MTBN1, MTBN2, MTBN3, MTBN4, MTBN5, MTBN6, MTBN7 or MTBN8, as depicted in FIGS. 1A and 1B , or a second amino acid sequence identical to the first amino acid sequence with conservative substitutions; the polypeptide has Mycobacterium tuberculosis specific antigenic and immunogenic properties. Also included in the invention is an isolated portion of the above DNA molecule. The portion of the DNA molecule encodes a segment of the polypeptide shorter than the full-length polypeptide, and the segment has Mycobacterium tuberculosis specific antigenic and immunogenic properties. Other embodiments of the invention are vectors containing the above DNA molecules and transcriptional and translational regulatory sequences operationally linked to the DNA sequence; the regulatory sequences allow for expression of the polypeptide or functional segment encoded by the DNA sequence in a cell. The invention encompasses cells (e.g., eukaryotic and prokaryotic cells) transformed with the above vectors.
[0006] The invention encompasses compositions containing any of the above vectors and a pharmaceutically acceptable diluent or filler. Other compositions (to be used, for example, as DNA vaccines) can contain at least two (e.g., three, four, five, six, seven, eight, nine, ten, twelve, fifteen, or twenty) DNA sequences, each encoding a polypeptide of the Mycobacterium tuberculosis complex or a functional segment thereof, with the DNA sequences being operationally linked to transcriptional and translational regulatory sequences which allow for expression of each of the polypeptides in a cell of a vertebrate. In such compositions, at least one (e.g., two, three, four, five, six, seven, or eight) of the DNA sequences is one of the above DNA molecules of the invention. The encoded polypeptides will preferably be those not encoded by the genome of cells of the BCG strain of M. bovis.
[0007] The invention also features an isolated polypeptide with a first amino acid sequence that can be the sequence of the polypeptide MTBN1, MTBN2, MTBN3, MTBN4, MTBN5, MTBN6, MTBN7 or MTBN8 as depicted in FIGS. 1A and 1B , or a second amino acid sequence identical to the first amino acid sequence with conservative substitutions. The polypeptide has Mycobacterium tuberculosis specific antigenic and immunogenic properties. Also included in the invention is an isolated segment of this polypeptide, the segment being shorter than the full-length polypeptide and having Mycobacterium tuberculosis specific antigenic and immunogenic properties. Other embodiments are compositions containing the polypeptide, or functional segment, and a pharmaceutically acceptable diluent or filler. Compositions of the invention can also contain at least two (e.g., three, four, five, six, seven, eight, nine, ten, twelve, fifteen, or twenty) polypeptides of the Mycobacterium tuberculosis complex, or functional segments thereof, with at least one of the at least two (e.g., two, three, four, five, six, seven, or eight) polypeptides having the sequence of one of the above described polypeptides of the invention. The polypeptides will preferably be those not encoded by the genome of cells of the BCG strain of M. bovis.
[0008] The invention also features methods of diagnosis. One embodiment is a method involving: (a) administration of one of the above polypeptide compositions to a subject suspected of having or being susceptible to Mycobacterium tuberculosis infection; and (b) detecting an immune response in the subject to the composition, as an indication that the subject has or is susceptible to Mycobacterium tuberculosis infection. An example of such a method is a skin test in which the test substance (e.g., compositions containing one or more of MTBN1-MTBN8) is injected intradermally into the subject and in which a skin delayed-type hypersensitivity response is tested for. Another embodiment is a method that involves: (a) providing a population of cells containing CD4 T lymphocytes from a subject; (b) providing a population of cells containing antigen presenting cells (APC) expressing a major histocompatibility complex (MHC) class II molecule expressed by the subject; (c) contacting the CD4 lymphocytes of (a) with the APC of (b) in the presence of one or more of the polypeptides, functional segments, and or polypeptide compositions of the invention; and (d) determining the ability of the CD4 lymphocytes to respond to the polypeptide, as an indication that the subject has or is susceptible to Mycobacterium tuberculosis infection. Another diagnostic method of the invention involves: (a) contacting a polypeptide, a functional segment, or a polypeptide/functional segment composition of the invention with a bodily fluid of a subject; (b) detecting the presence of binding of antibody to the polypeptide, functional segment, or polypeptide/functional segment composition, as an indication that the subject has or is susceptible to Mycobacterium tuberculosis infection.
[0009] Also encompassed by the invention are methods of vaccination. These methods involve administration of any of the above polypeptides, functional segments, or DNA compositions to a subject. The compositions can be administered alone or with one or more of the other compositions.
[0010] As used herein, an “isolated DNA molecule” is a DNA which is one or both of: not immediately contiguous with one or both of the coding sequences with which it is immediately contiguous (i.e., one at the 5′ end and one at the 3′ end) in the naturally-occurring genome of the organism from which the DNA is derived; or which is substantially free of DNA sequence with which it occurs in the organism from which the DNA is derived. The term includes, for example, a recombinant DNA which incorporated into a vector, e.g., into an autonomously replicating plasmid or virus, or into the genomic DNA of a prokaryote or eukaryote, or which exists as a separate molecule (e.g., a cDNA or a genomic fragment produced by PCR or restriction endonuclease treatment) independent of other DNA sequences. Isolated DNA also includes a recombinant DNA which is part of a hybrid DNA encoding additional M. tuberculosis polypeptide sequences.
[0011] “DNA molecules” include cDNA, genomic DNA, and synthetic (e.g., chemically synthesized) DNA. Where single-stranded, the DNA molecule may be a sense strand or an antisense strand.
[0012] An “isolated polypeptide” of the invention is a polypeptide which either has no naturally-occurring counterpart, or has been separated or purified from components which naturally accompany it, e.g., in M. tuberculosis bacteria. Typically, the polypeptide is considered “isolated” when it is at least 70%, by dry weight, free from the proteins and naturally-occurring organic molecules with which it is naturally associated.
[0013] Preferably, a preparation of a polypeptide of the invention is at least 80%, more preferably at least 90%, and most preferably at least 99%, by dry weight, the peptide of the invention. Since a polypeptide that is chemically synthesized is, by its nature, separated from the components that naturally accompany it, the synthetic polypeptide is “isolated.”
[0014] An isolated polypeptide of the invention can be obtained, for example, by extraction from a natural source (e.g., M. tuberculosis bacteria); by expression of a recombinant nucleic acid encoding the polypeptide; or by chemical synthesis. A polypeptide that is produced in a cellular system different from the source from which it naturally originates is “isolated,” because it will be separated from components which naturally accompany it. The extent of isolation or purity can be measured by any appropriate method, e.g., column chromatography, polyacrylamide gel electrophoresis, or HPLC analysis.
[0015] The polypeptides may contain a primary amino acid sequence that has been modified from those disclosed herein. Preferably these modifications consist of conservative amino acid substitutions. Conservative substitutions typically include substitutions within the following groups: glycine and alanine; valine, isoleucine, and leucine; aspartic acid and glutamic acid; asparagine and glutamine; serine and threonine; lysine and arginine; and phenylalanine and tyrosine.
[0016] The terms “protein” and “polypeptide” are used herein to describe any chain of amino acids, regardless of length or post-translational modification (for example, glycosylation or phosphorylation). Thus, the term “ Mycobacterium tuberculosis polypeptide” includes full-length, naturally occurring Mycobacterium tuberculosis protein, as well a recombinantly or synthetically produced polypeptide that corresponds to a full-length naturally occurring Mycobacterium tuberculosis protein or to particular domains or portions of a naturally occurring protein. The term also encompasses a mature Mycobacterium tuberculosis polypeptide which has an added amino-terminal methionine (useful for expression in prokaryotic cells) or any short amino acid sequences useful for protein purification by affinity chromatography, e.g., polyhistidine for purification by metal chelate chromatography.
[0017] As used herein, “immunogenic” means capable of activating a primary or memory immune response. Immune responses include responses of CD4+ and CD8+T lymphocytes and B-lymphocytes. In the case of T lymphocytes, such responses can be proliferative, and/or cytokine (e.g., interleukin (IL)-2, IL-3, IL-4, IL-5, IL-6, IL-12, IL-13, IL-15, tumor necrosis factor-a (TNF-a), or interferon-y (IFN-y))-producing, or they can result in generation of cytotoxic T-lymphocytes (CTL). B-lymphocyte responses can be those resulting in antibody production by the responding B lymphocytes.
[0018] As used herein, “antigenic” means capable of being recognized by either antibody molecules or antigen-specific T cell receptors (TCR) on activated effector T cells (e.g., cytokine-producing T cells or CTL).
[0019] Thus, polypeptides that have “ Mycobacterium tuberculosis specific antigenic properties” are polypeptides that: (a) can be recognized by and bind to antibodies elicited in response to Mycobacterium tuberculosis organisms or wild-type Mycobacterium tuberculosis molecules (e.g., polypeptides); or (b) contain subsequences which, subsequent to processing of the polypeptide by appropriate antigen presenting cells (APC) and bound to appropriate major histocompatibility complex (MHC) molecules, are recognized by and bind to TCR on effector T cells elicited in response to Mycobacterium tuberculosis organisms or wild-type Mycobacterium tuberculosis molecules (e.g., polypeptides).
[0020] As used herein, polypeptides that have “ Mycobacterium tuberculosis specific immunogenic properties” are polypeptides that: (a) can elicit the production of antibodies that recognize and bind to Mycobacterium tuberculosis organisms or wild-type Mycobacterium tuberculosis molecules (e.g., polypeptides); or (b) contain subsequences which, subsequent to processing of the polypeptide by appropriate antigen presenting cells (APC) and bound to appropriate major histocompatibility complex (MHC) molecules on the surface of the APC, activate T cells with TCR that recognize and bind to peptide fragments derived by processing by APC of Mycobacterium tuberculosis organisms or wild-type Mycobacterium tuberculosis molecules (e.g., polypeptides) and bound to MHC molecules on the surface of the APC. The immune responses elicited in response to the immunogenic polypeptides are preferably protective. As used herein, “protective” means preventing establishment of an infection or onset of a disease or lessening the severity of a disease existing in a subject. “Preventing” can include delaying onset, as well as partially or completely blocking progress of the disease.
[0021] As used herein, a “functional segment of a Mycobacterium tuberculosis polypeptide” is a segment of the polypeptide that has Mycobacterium tuberculosis specific antigenic and immunogenic properties.
[0022] Where a polypeptide, functional segment of a polypeptide, or a mixture of polypeptides and/or functional segments have been administered (e.g., by intradermal injection) to a subject for the purpose of testing for a M. tuberculosis infection or susceptibility to such an infection, “detecting an immune response” means examining the subject for signs of an immunological reaction to the administered material, e.g., reddening or swelling of the skin at the site of an intradermal injection. Where the subject has antibodies to the administered material, the response will generally be rapid, e.g., 1 minute to 24 hours. On the other hand, a memory or activated T cell reaction of pre-immunized T lymphocytes in the subject is generally slower, appearing only after 24 hours and being maximal at 24-96 hours.
[0023] As used herein, a “subject” can be a human subject or a non-human mammal such as a non-human primate, a horse, a bovine animal, a pig, a sheep, a goat, a dog, a cat, a rabbit, a guinea pig, a hamster, a rat, or a mouse.
[0024] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. In case of conflict, the present document, including definitions, will control. Preferred methods and materials are described below, although methods and materials similar or equivalent to those described herein can be used in the practice or testing of the present invention. Unless otherwise indicated, these materials and methods are illustrative only and are not intended to be limiting.
[0025] All publications, patent applications, patents and other references mentioned herein are illustrative only and not intended to be limiting.
[0026] Other features and advantages of the invention, e.g., methods of diagnosing M. tuberculosis infection, will be apparent from the following description, from the drawings and from the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] FIGS. 1A and 1B are a depiction of the amino acid sequences of M. tuberculosis polypeptides MTBN1-MTBN8 (SEQ ID NOS:1-8, respectively).
[0028] FIGS. 2A and 2B are a depiction of the nucleotide sequences of the coding regions (mtbn1-mtbn8) encoding MTBN1-MTBN8 (SEQ ID NOS:9-16, respectively).
[0029] FIG. 3 is a bar graph showing the delayed-type hypersensitivity responses induced by intradermal injection of 3 different test reagents in female guinea pigs that had been either infected with M. tuberculosis cells or sensitized with BCG or M. avium cells.
DETAILED DESCRIPTION
[0030] The genome of M. tuberculosis [Cole et al. (1998) Nature 393: 537-544] contains open reading frames (ORFs) that have been deleted from the avirulent BCG strain.
[0031] The polypeptides encoded by these ORFs are designated herein “ M. tuberculosis BCG Negative” polypeptides (“MTBN”) and the ORFs are designated “mtbn.” The invention is based on the discovery that a MTBN polypeptide (MTBN4) elicited a skin response in animals infected with M. tuberculosis , but not in animals sensitized to either BCG or M. avium , a non- M. tuberculosis -complex strain of mycobacteria (see Example 1 below). These findings indicate that MTBN (e.g., MTBN1-MTBN8) can be used in diagnostic tests that discriminate infection of a subject by M. tuberculosis from exposure to both mycobacteria other than the M. tuberculosis -complex and BCG. The M. tuberculosis -complex includes M. tuberculosis, M. bovis, M. microti , and M. africanum . Thus they can be used to discriminate subjects exposed to M. tuberculosis , and thus potentially having or being in danger of having tuberculosis , from subjects that have been vaccinated with BCG, the most widely used tuberculosis vaccine. Diagnostic assays that are capable of such discrimination represent a major advance that will greatly reduce wasted effort and consequent costs resulting from further diagnostic tests and/or therapeutic procedures in subjects that have given positive results in less discriminatory diagnostic tests.
[0032] Furthermore, the results in Example 1 show that MTBN4, as expressed by whole viable M. tuberculosis organisms, is capable of inducing a strong immune response in subjects infected with the organisms and thus has the potential to be a vaccine.
[0033] The MTBN polypeptides of the invention include, for example, polypeptides encoded within the RD1, RD2, and RD3 regions of the M. tuberculosis genome [Mahairas et al. (1996) J. Bacteriol. 178: 1274-1282]. Of particular interest are polypeptides encoded by ORFs within the RD1 region of the M. tuberculosis genome. However, the invention is not restricted to the RD1, RD2, and RD3 region encoded polypeptides and includes any polypeptides encoded by ORFs contained in the genome of one or more members of the M. tuberculosis genome and not contained in the genome of BCG. The amino acid sequences of MTBN1-MTBN8 are shown in FIGS. 1A and 1B and the nucleotide sequences of mtbn1-mtbn8 are shown in FIGS. 2A and 2B .
[0034] The invention encompasses: (a) isolated DNA molecules containing mtbn sequences (e.g., mtbn1-mtbn8) encoding MTBN polypeptides (e.g., MTBN1-MTBN8) and isolated portions of such DNA molecules that encode polypeptide segments having antigenic and immunogenic properties (i.e., functional segments); (b) the MTBN polypeptides themselves (e.g., MTBN1-MTBN8) and functional segments of them; (c) antibodies (including antigen binding fragments, e.g., F (ab′) 2, Fab, Fv, and single chain Fv fragments of such antibodies) that bind to the MTBN polypeptides (e.g., MTBN1-MTBN8) and functional segments; (d) nucleic acid molecules (e.g., vectors) containing and capable of expressing one or more of the mtbn (e.g., mtbn1-mtbn8) sequences and portions of DNA molecules; (e) cells (e.g., bacterial, yeast, insect, or mammalian cells) transformed by such vectors; (f) compositions containing vectors encoding one or more M. tuberculosis polypeptides (or functional segments) including both the MTBN (e.g., MTBN1-MTBN8) polypeptides (or functional segments thereof) and previously described M. tuberculosis polypeptides such as ESAT-6, 14 kDa antigen, MPT63, 19 kDa antigen, MPT64, MPT51, MTC28, 38 kDa antigen, 45/47 kDa antigen, MPB70, Ag85 complex, MPT53, and KatG (see also U.S. application Ser. No. 08/796,792); (g) compositions containing one or more M. tuberculosis polypeptides (or functional segments), including both the polypeptides of the invention and previously described M. tuberculosis polypeptides such as those described above; (h) compositions containing one or more of the antibodies described in (c); (i) methods of diagnosis involving either (1) administration (e.g., intradermal injection) of any of the above polypeptide compositions to a subject suspected of having or being susceptible to M. tuberculosis infection, (2) in vitro testing of lymphocytes (B-lymphocytes, CD4 T lymphocytes, and CD8 T lymphocytes) from such a subject for responsiveness (e.g., by measuring cell proliferation, antibody production, cytokine production, or CTL activity) to any of the above polypeptide compositions, (3) testing of a bodily fluid (e.g., blood, saliva, plasma, serum, urine, or semen or a lavage such as a bronchioalveolar lavage, a vaginal lavage, or lower gastrointestinal lavage) for antibodies to the MTBN polypeptides (e.g., MTBN1-MTBN8) or functional segments thereof, or the above-described polypeptide compositions; (4) testing of a bodily fluid (e.g., as above) for the presence of M. tuberculosis , MTBN (e.g., MTBN1-MTBN8) polypeptides or functional segments thereof, or the above-described polypeptide compositions in assays using the antibodies described in (c); and (5) testing of a tissue (e.g., lung or bronchial tissue) or a body fluid (e.g., as above) for the presence of nucleic acid molecules (e.g., DNA or RNA) encoding MTBN polypeptides (e.g., MTBN1-MTBN8) (or portions of such a nucleic acid molecules) using nucleic acid probes or primers having nucleotide sequences of the nucleic molecules, portions of the nucleic molecules, or the complements of such molecules; and (j) methods of vaccination involving administration to a subject of the compositions of either (0, (g), (h) or a combination of any two or even all 3 compositions.
[0035] With respect to diagnosis, purified MTBN proteins, functional segments of such proteins, or mixtures of proteins and/or the functional fragments have the above-described advantages of discriminating infection by M. tuberculosis from either infection by other bacteria, and in particular, non-pathogenic mycobacteria, or from exposure (by, for example, vaccination) to BCG.
[0036] Furthermore, compositions containing the proteins, functional segments of the proteins, or mixtures of the proteins and/or the functional segments allows for improved quality control since “batch-to-batch” variability is greatly reduced in comparison to complex mixtures such as purified protein derivative (PPD) of tuberculin.
[0037] The use of the above-described polypeptide and nucleic acid reagents for vaccination also provides for highly specific and effective immunization. Since the virulent M. tuberculosis polypeptides encoded by genes absent from avirulent BCG are likely to be mediators of virulence, immunity directed to them can be especially potent in terms of protective capacity. Where vaccination is performed with nucleic acids both in vivo and ex vivo methods can be used. In vivo methods involve administration of the nucleic acids themselves to the subject and ex vivo methods involve obtaining cells (e.g., bone marrow cells or fibroblasts) from the subject, transducing the cells with the nucleic acids, preferably selecting or enriching for successfully transduced cells, and administering the transduced cells to the subject. Alternatively, the cells that are transduced and administered to the subject can be derived from another subject. Methods of vaccination and diagnosis are described in greater detail in U.S. Pat. No. 6,087,163, the disclosure of which is incorporated herein by reference in its entirety.
[0038] The following example is meant to illustrate, not limit the invention.
Example 1
MTBN4 Elicits a Specific Skin Reaction in Guinea Pigs Infected with M. tuberculosis
[0039] Four groups of outbred female guinea pigs (18 per group) were used to test the usefulness of the MTBN4 polypeptide as a M. tuberculosis -specific diagnostic reagent. The four groups were treated as follows.
[0040] Group 1 animals were infected by aerosol with approximately 100 M. tuberculosis strain H37Rv cells.
[0041] Group 2 animals were sensitized intradermally with 106 live M. bovis BCG Japanese cells.
[0042] Group 3 animals were sensitized intradermally with 106 live M. avium cells.
[0043] Group 4 animals were mock-sensitized by intradermal injection with saline.
[0044] Seven weeks after infection or sensitization, the animals were injected intradermally with 1 μg of PPD (6 animals from each group), 2 μg of purified recombinant MPT64 (6 animals from each group), or 2 μg of MTBN4 (6 animals from each group). The diameter of the resulting erythema was measured 24 hours later. Data are expressed as mean diameter of erythema (in mm) and standard deviations are indicated ( FIG. 3 ).
[0045] No erythema was detected in the group 4 animals with any test substance and thus no data are shown for this group. On the other hand, group 1 animals (solid bars) showed a significant response with all three test substances. Group 2 animals (open bars) showed a significant response to PPD and MPT64 but not MTBN4.
[0046] Group 3 animals showed a significant response to PPD only (hatched bars).
[0047] Thus, PPD which contains antigenic/immunogenic molecules common to the M. tuberculosis-complex as well as other mycobacterial strains, gave the least discriminatory results in that it induced responses in animals infected with or sensitized to mycobacteria of the M. tuberculosis -complex ( M. tuberculosis and BCG) as well as another non-pathogenic mycobacterium ( M. avium ).
[0048] While MPT64, which is encoded and expressed by both M. tuberculosis and BCG, did not elicit a response in animals infected with M. avium , it did elicit responses in both the M. tuberculosis infected and the BCG sensitized animals. Finally, MTBN4 elicited a response in only the M. tuberculosis animals. Thus it induced the most specific response and, most importantly, allowed for discrimination between animals infected with M. tuberculosis and those sensitized to BCG.
[0049] Although the invention has been described with reference to the presently preferred embodiment, it should be understood that various modifications can be made without departing from the spirit of the invention. Accordingly, the invention is limited only by the following claims. | The present invention is directed to proteins expressed by Mycobacterium tuberculosis and not by BCG and their use as vaccines. | 6 |
BACKGROUND OF THE INVENTION
This invention relates generally to a security seal of the kind used for securing transport containers, warehouse doors, army depots, valves, taps in mobile petroleum carriers and the like, so as to protect against unauthorized tampering, and in particular, to a security seal of this type which is reusable.
Security seals are generally supplied for single use, so that removing the seal can only be accomplished by breaking the seal in such a manner that it is no longer usable. Security seals are commonly mounted through respective apertures projecting from adjacent doors in a transport container and are mounted after loading the transport container and prior to transit thereof, so that when the transport container reaches its destination inspection of the security seal may serve to ensure that the doors of the container have not been tampered with during transit.
After removal of the security seal from the doors of the transport container, the container is unloaded and very often is then sent on to a further destination with a new load, thereby requiring the fixation of another security seal. Although security seals are relatively inexpensive, it will be appreciated that haulage contractors must purchase security seals in mass quantities and that the ability to reuse a security seal several times would result in very significant savings to the haulage contractor. However, to date the design of conventional security seals has militated against their reuse. On the one hand, the security seal must be somehow broken in order to permit access to the load and, on the other hand, such breakage is itself indicative of unauthorized tampering with the security seal if this is done during transit.
It is therefore desirable to provide a reusable security seal that is inexpensive to manufacture, simple to use and decreases costs to the end-user.
SUMMARY OF THE INVENTION
Generally speaking, in accordance with the invention, a reusable security seal includes a first member including a plurality of frangible sections each frangible section having a first clasp portion and an identity associated therewith. A housing is coupled to a first end of the first member and includes a second clasp portion disposed at least partially therein for cooperating with the first clasp portion. The first member and the housing form a closed loop extending between the cooperating clasp portion. And the first clasp portion and the second clasp portion are adapted to lock, so that pressure applied to the closed loop will cause at least one of the frangible sections to break before the clasp portion will unlock.
Preferably, the first member is divided into a plurality of frangible sections, each having a respective identity code embossed thereon (i.e. an identification number) and having an aperture formed therein which engages a resiliently mounted claw within the housing. In the preferred embodiment, the housing is substantially closed and includes a pair of slots at opposite ends thereof. One slot receives the frangible section of the first member inserted therein. The frangible member cannot be removed from this slot. The second slot is for the frangible member to be removed from.
The frangible member is insertable within the first slot and removable from the second slot of the housing because the claw of the housing engages the aperture of the frangible section to lock the frangible section in place. When the frangible section is separated from the remainder of the first member it can be removed from the housing through the second slot, because the aperture in the frangible section can ride over the resiliently mounted claw in the direction of the second slot. Alternatively, pulling on the closed loop (pulling the frangible section toward the first slot), causes the claw to engage an inside edge of the aperture thereby preventing withdrawal of the flexible strip from the housing. This in essence locks the frangible member in the housing.
In the preferred manner of use, the frangible section, locked within the housing is the section that is broken (i.e., separated from the first member). The frangible section remaining inside the housing is removed from the housing by pulling on a free end of the frangible section which protrudes from the housing. The frangible section must be pulled along the same direction as it was inserted into the housing to be removed (it can not be removed from the same slot it was inserted into).
Accordingly, it is an object of the invention to provide an improved reusable security seal.
It is another object of the invention to provide a reusable security seal that includes a plurality of frangible sections each having an identity associated therewith, and that identity is optionally hidden until the seal is broken and the identity is checked.
Still another object of the invention is to provide a reusable security seal that is low cost to manufacture.
Yet another object of the invention is to provide a reusable security seal that reduces waste of raw materials and is more healthy for the environment then previous security seals.
Still a further object of the invention is to provide a reusable seal that is usable at least thirty times.
Still other objects and advantages of the invention will in part be obvious and will in part be apparent from the specification and drawings.
The invention accordingly comprises a product possessing the features, properties, and the relation of components which will be exemplified in the product hereinafter described, and the scope of the invention will be indicated in the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
For a fuller understanding of the invention, reference is had to the following description taken in connection with the accompanying drawings, in which:
FIG. 1 is an exploded perspective view of a reusable security seal in accordance with a first embodiment of the invention with select interior elements shown in phantom;
FIG. 2 is a perspective view of the preferred embodiment of the clasp element which is normally located within the housing of a reusable security seal;
FIG. 3 is a perspective view of a reusable security seal shown with the first (band) member fed through the first slot of the housing;
FIG. 4 is a partial cross-section view taken along line 4--4 of FIG. 3;
FIG. 5 is a partial cross-section view of a second embodiment of the invention; and
FIG. 6 is a partial cross-sectional view of a third embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIGS. 1 through 4 show a security seal according to a first embodiment of the invention, generally indicated at 8, which includes a flexible strip 10, a housing 11 and a clasp portion 12. Flexible strip 10 includes a plurality of frangible sections 13, 14 and 15 each having a respective aperture 16 therein, and a respective identify associated therewith comprising a serial number or identity code 17, embossed on a surface of flexible strip 10. (In the preferred embodiment, each seal will include at least thirty frangible sections.) Identity code 17 provides an identity for each frangible section 13, 14 and 15. Preferably, identity code 17 includes at least 3 digits. The identity code 17 can also include an alphabetic code which further expands the number of unique codes. The frangible sections are defined by grooves 9 formed in flexible strip 10 (the grooves are shown as dashed lines in the perspective views).
A first end 18 of the flexible strip 10 is provided with an aperture 19 and each of the frangible sections 13, 14 and 15 has associated therewith a corresponding lateral protrusion 20. Lateral protrusion 20 constitutes an arrest means which is itself frangible from flexible strip 10 attached to the respective section. As discussed in more detail below, when the flexible strip 10 is inserted into housing 11 the respective lateral protrusion 20 associated with the frangible section proximate to the frangible section disposed within housing 11, engages housing 11 and prevents further insertion of flexible strip 10 into housing 11.
Housing 11 comprises an essential fully enclosed rectangular box shaped member, and includes a lower surface 23 and an upper surface 24, a pair of sidewalls 25 and 26 and a pair of end walls 27 and 28. End walls 27 and 28 define a pair of slots 29 and 30 disposed in the respective end walls 27 and 28 in facing relation. The clasp portion 12 is provided at a first end thereof with an aperture 32 and is provided with an upwardly directed claw 34 at an opposite end thereof. Clasp 12 also includes two downwardly directed legs 31 that are provided to bear against the lower surface 23 of housing 11. Legs 31 are provided below window 42 in upper surface 24 to prevent tampering with the seal by deflecting clasp 12 through window 42. When assembled, clasp 12 is mounted within housing 11, such that the end of clasp 12 which contains aperture 32 abuts lower surface 23 of housing 11, and the opposite end of clasp 12 which contains claw 34 abuts the upper surface 24 of the housing 11, and is accommodated within a generally bulbous protrusion 36 of housing 11. The first end 18 of flexible strip 10 is inserted into first slot 29 of housing 11 and a single expansion rivet 40 is disposed within aperture 19 of flexible strip 10, aperture 32 of clasp 12 and an aperture 38 of lower surface 23 of housing 11. Rivet 40 fixedly secures clasp 12 and flexible member 10 to housing 11.
Operation of security seal 8 is facilitated by providing a window 42 in the upper surface 24 of housing 11. Window 42 permits identify code 17 of the frangible sections to be displayed therethrough when the frangible section is inserted into housing 11.
First end 18 of flexible strip 10 eventuates from first slot 29 of housing 11 while a second end 44 of flexible strip 10 is inserted into first slot 29 of housing 11 and emerges from second slot 30 thereof. First slot 29 is designed to be thick enough to accommodate only two thicknesses of flexible strip 10, and second slot 30 is designed to accommodate only a single thickness of flexible strip 10. This configuration prevents tampering with the seal through slots 29 and 30 by unauthorized personnel. Furthermore, window 42 is configured to be small enough (preferably not larger than 4 mm) that the seal can not be tampered with through window 42. An additional seal, formed of plexiglass or the like can be optionally coupled to housing 11 proximate to window 42 to prevent tampering with the seal through the window opening.
Each frangible section shown in FIG. 1 preferably has associated therewith a three digit serial number (identity code 17), thus allowing one thousand possible permutations. In order to allow a larger number of unique identities to be associated with the security seals, each identity code 17 can be provided with two portions; one of which is embossed on flexible strip 10 and the other of which is associated with housing 11. Thus, in the specific example shown in the figure, the provision of two additional digits on housing 11 provides for a maximum of five digits thereby increasing the maximum number of permutations to 100,000. It is also possible to provide a multidigit serial number on housing 11, so that each housing 11 is distinct from all others. This would further expand the number of unique seals. An added measure of security can be achieved by numbering the frangible section in a random sequence rather than sequentially as depicted in the figures. In other words, the exact coding system used can be modified to suit any particular purpose.
In use, flexible strip 10 is passed through opposing handles of a container or other closed structure (not shown) and a free end 44 (constituting a second end) of flexible strip 10 is inserted into the first slot 29 of housing 11 so as to emerge from second slot 30 therein while positioning identity code 17 of the endmost frangible section 13 in alignment with window 42 of housing 11. When inserted in this manner, flexible strip 10 forms a closed loop depending from housing 11. Endmost frangible section 13 which is disposed within housing 11 depresses resilient clasp portion 12 until aperture 16 of endmost frangible section 13, engages claw 34 in clasp portion 12. Clasp portion 12 then springs upward slightly so that the claw 34 emerges through aperture 16 and is seated within bulbous protrusion 36, thereby preventing removal of flexible strip 10 from housing portion 11 by pulling on the closed loop formed by flexible strip 10. The engagement of aperture 16, constituting a first clasp portion, and claw 34, constituting a second clasp portion, form a locking clasp arrangement. The free end 44 of flexible strip 10 protrudes from second slot 30 of housing 11. Second end 44 of flexible strip 10 cannot be extracted through second slot 30 of housing 11 due to the abutment of lateral protrusion 20 against housing 11.
When it is desired to remove security seal 8 from sealing a container, the endmost frangible section 13 is preferably broken from the remainder of flexible strip 10. This leaves the endmost frangible section 13 within housing 11 while, at the same time, leaving lateral protrusion 20 still connected to the remainder of flexible strip 10. Since, in this condition, lateral protrusion 20 is no longer connected to endmost frangible section 13, the latter may be removed from housing 11 simply by pulling free end 44 of flexible strip 10, whereupon endmost frangible section 13 is extracted from housing 11 without damaging clasp 12 therein.
Lateral protrusion 20 associated with what was endmost frangible section 13 of flexible strip 10 and which remains connected to the remainder of flexible strip 10 is removed from flexible strip 10, so that second frangible section 14 bearing its respective identity code 17 now becomes the endmost frangible section, and the security seal may be reused, as required, until all the frangible sections thereof have been broken.
It is desirable to have the identity code 17 covered, so that it is not visible by the shipper, or transporter of the container being shipped. Accordingly, with particular reference to FIG. 4, it is seen that a laminate, or cover layer 48 is provided and disposed on top of flexible member 10 to cover identity codes 17. This is why each identity code 17 is shown in phantom in FIGS. 1 and 3, except for the identity code appearing within window 42, where the cover layer 48 is removed, so that only the identity code appearing in the window is visible. In an alternative embodiment, the cover layer 48 is not removed from the identity code until after the seal is broken and the frangible section is extracted through second slot 30 of housing 11.
Particular attention is next directed to the second embodiment of the invention disclosed in FIG. 5. FIG. 5 depicts a security seal, generally indicated at 108, which includes a flexible strip 110, a housing 111, and a clasp 112. The flexible strip includes a plurality of frangible sections (not shown, but the same as shown in FIGS. 1 and 2). Housing 111 is formed in the same configuration as disclosed above with regard to FIGS. 1-4, and flexible member 110 similarly includes substantially the same configuration as disclosed above.
The difference between security seal 8 and security seal 108 is in that flexible member 110 of FIG. 5 is formed integral with clasp 112. In FIG. 5, housing 111 comprises an essentially fully enclosed rectangular box-shaped member and includes a lower surface 123. A clasp portion 112 is provided at a first end with an aperture 132 which abuts against the lower surface 123 of housing 111. The opposite end of clasp 112 contains a claw 126 which abuts against an upper surface 124 of housing 111, and is accommodated within a generally bulbous protrusion 136 therein.
In the embodiment of FIG. 5, clasp portion 112 is integrally formed with flexible strip 110. In this embodiment, flexible strip 110 is semi-rigid, such that when doubled over in the region of clasp 112, claw 126 (which includes a double thick piece of flexible strip 110 coupled on itself) is rigid enough to lock flexible strip 110 within housing 111. Since clasp 112 is integrally formed with flexible strip 110, a single expansion rivet 140 is disposed through an aperture 132 in the double thick claw 112, and through an aperture 138 in bottom wall 123 of housing 111. The claw portion receives its rigidity and shape by being doubled over and coupled via normal processes, using, for example, adhesive, heat treatment or the like.
The third embodiment, as disclosed in FIG. 6, is substantially the same as the first embodiment of 1-4; however, the only variation is that the apertures 16 formed in flexible strip 10 are not fully cut out. In other words, an additional locking feature is provided in the clasping technique. A flap 200 is provided proximate to aperture 16, and in locking engagement with claw 34 of clasp 12, thereby providing an additional locking feature.
Each embodiment includes an additional element that can be included in the other embodiments. For example, flap 200 can be incorporated within the embodiment of FIG. 5 to add greater strength to the clasp.
It will be appreciated that modifications may also be made to the security seal without departing from the spirit of the invention. For example, although the provision of the window 42 allows for easy manufacture of the security seal, as described, and also allows display of the identity code 17 therethrough, it may be preferred to emboss or otherwise mark the identity code on the protruding end of the flexible strip or, indeed, to identify each frangible section by means of a marking on an adjacent portion of the flexible strip. Furthermore, by eliminating window 42 the identity of the present frangible member can be kept a secret until the seal is broken.
While the flexible strip 10 is depicted as being formed of plastic, and housing 11 is depicted as being formed of metal, all components of the security seal may be formed of either metal or suitable plastic.
It is also clear that while the provision of lateral protrusion 20 is advantageous and prevents undesired waste of unused sections of the flexible strip, the lateral protrusion 20 is optional in the sense that the principle of the invention may be employed, even without the provision of lateral protrusion 20.
It will thus be seen that the objects set forth above, among those made apparent from the preceding description, are efficiently attained and, since certain changes may be made in the above article without departing from the spirit and scope of the invention, it is intended that all matter contained in the above description and shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.
It is also to be understood that the following claims are intended to cover all of the generic and specific features of the invention herein described, and all statements of the scope of the invention which, as a matter of language, might be said to fall therebetween. | A reusable security seal comprising a first member including a plurality of frangible sections, each frangible section having a first clasp portion and an identity associated therewith is provided. A housing is coupled to a first end of the first member and includes a second clasp portion disposed at least partially therein for cooperating with the first clasp portion. The first member and the housing form a closed loop extending between the cooperating clasp portions. The first clasp portion and the second clasp portion are adapted for substantially locking engagement, so that pressure applied to the closed loop will cause at least one of the frangible sections to break before the clasp portions will unlock. | 8 |
TECHNICAL FIELD
This invention relates generally to laser marking of products and, more particularly, relates to detection and indication of the distance between a laser marking apparatus and a product to be marked.
BACKGROUND OF THE INVENTION
There exist many different ways to place printed matter on a product package, including ink printing on the product, laser marking on the product, and ink or laser preprinting of a label to be placed upon the product. Of these, laser marking the product is often the most desirable alternative because of its low cost and easy adaptation to different marking jobs. It is especially useful in putting final markings, such as expiration dates and the like, on completed products. The technique of laser marking entails directing a focussed beam of light generated by a laser at a product. The focussed laser light marks the surface by burning caused by absorption of the light and a transformation of that light, or photon, energy into heat energy. Alternatively, the photons of the focussed laser light may interact directly with the material of the target without an intermediate transformation into heat energy.
In either case, the degree of visual change in the target material will be a function to some extent of the energy density in the focussed laser light, which is partly a function of the beam focus. Additionally, the sharpness of the mark may also be affected by the degree of focus of the laser beam. Accordingly, it is important that the distance between the product to be marked and the laser light focussing lens closely match the focal length of the lens. Additionally, the laser light focussing lens is often changed in order to facilitate the making of different sized markings. It is desirable in such cases that an operator be able to easily and quickly adjust the distance between lens and product to match the desired distance.
Many lasers used for marking applications emit light that falls outside of the human visible spectrum, and thus visual optimization of the focus is impractical. Even where the laser light is visible, it is often difficult to visually optimize the focus. Accordingly, in the past, operators of industrial laser marking systems have manually measured the distance between the lens and product, using a ruler, and have adjusted the distance to match the known focal length of the lens. Alternatively, or in addition, the distance is sometimes varied as several trial pieces of product are marked, and the distance is fixed when the product appears to be properly marked. Neither of these methods is fast or easy, and the second method involves wasting the improperly marked trial pieces.
A method and apparatus are needed whereby a laser marking equipment operator may receive a human-perceivable indication of the distance from lens to product to be marked, so that such distance may be set equal to the focal length of the lens, or to another desired distance.
SUMMARY OF THE INVENTION
According to an embodiment of the present invention, a distance measuring sensor is mounted proximal to and at the same vertical height as a laser light focussing lens, in an industrial laser marking apparatus. Indicators actuated by the distance measuring sensor give a human-perceivable indication of the distance between the sensor and a target. Due to the proximal placement of the distance measuring sensor to the laser light focussing lens, the human-perceivable indication serves to indicate the distance between the laser light focussing lens and the target as well. The human-perceivable indication may be comprised of light emitting diodes (LED's) which are activated selectively to indicate the measured distance.
BRIEF DESCRIPTION OF THE DRAWINGS
While the appended claims set forth the features of the present invention with particularity, the invention, together with its objects and advantages, may be best understood from the following detailed description taken in conjunction with the accompanying drawings of which:
FIG. 1 is a schematic diagram generally illustrating an operating environment and mode of operation for a sensor system according to an embodiment of the invention;
FIG. 2 is a flow chart of operations according to an embodiment of the invention;
FIG. 3 is a schematic diagram of a circuit usable in an embodiment of the invention to activate a distance-indicating LED; and
FIG. 4 is a block diagram illustrating a mode of operation of an alternative embodiment of the invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Turning to the drawings, wherein like reference numerals refer to like elements, FIG. 1 illustrates a preferred operating environment and mode of operation for a sensor system embodying the invention. An industrial laser marking apparatus has a movable laser head 1 for directing the output of a laser to a product 2 to be marked. A lens mount 3 is disposed to alternately receive different output lenses having different focal lengths. Typically, the necessary output lens focal length is a function of the size of the features to be marked. Accordingly, if the size of the marked features is to be changed, for example from a smaller to a larger font size, then the output lens focal length is also changed.
Product 2 to be marked traverses a path 4 which typically intersects and is locally perpendicular to the axis of the output laser beam, at a product position in front of the beam output. The position of the laser head 1 is typically movable at least along the axis of the output laser beam, while the position of the path 4 of the product 2 is typically not changeable along this axis. The distance between the output lens 5 and the path 4 of the product 2 to be marked is temporarily fixed during marking in accordance with the focal length of the current output lens 5 .
Preferably, a sensor unit 6 is fixedly mounted to a movable output of the laser apparatus via a clamp 7 , and an extension arm 8 . The sensor unit 6 is mounted such that a sensor element 9 is aligned with the laser output lens 5 . In such an embodiment, the distance from the laser output lens 5 to the products on the path 4 will correspond to the distance from the sensor element 9 in the sensor unit 6 to the products on the path 4 . Accordingly, any subsequent adjustment of the distance from the output lens 5 to the product path 4 will cause the distance from the sensor element 9 to the products on the path 4 to change by the same amount.
In a preferred embodiment, the sensor element 9 is an ultrasonic sensor such as the Hyde Park SM606A-BOB-00. This sensor comprises an ultrasonic transmitter and ultrasonic sensor. The sensor converts sensed distance into an analog output signal. Thus, as the product passes along the product path 4 in front of the sensor element 9 , the ultrasonic sensor generates an analog signal indicative of the distance 11 from the laser output lens 5 and the sensor element 9 to the products on the path 4 .
The sensor unit 6 has mounted thereon a human-perceivable indicator of the distance 11 . In a preferred embodiment, the human-perceivable indicator is an array of five LED's 10 which are sequentially disposed to light according to the distance 11 . Thus, in this embodiment, there exists in the array 10 an LED for each potential focal length. These focal lengths may be 2.5″, 3.75″, 5″, 7.5″, and 10″. Alternatively, there may be more or different desired focal lengths, each of which would preferably have a corresponding LED in the array 10 . The LED's may be of the same or different color, and are preferably disposed adjacent to a key 12 which explains the meaning of each. For example, the distance to which a given LED corresponds may be written on the key next to the appropriate LED.
The operation of this embodiment is shown in the flow chart of FIG. 2; with reference to the elements of FIG. 1 . Initially, in Step 1 a human operator selects an output lens 5 having a known focal length, based on desired laser marking font size or other appropriate criteria. This lens will be inserted into the lens mount 3 at any point in time prior to the commencement of laser marking. The human operator turns the printer on in Step 2 , supplying power and turning on the sensor unit 6 . Having a sample of the product to be marked stationarily or periodically disposed along the product path 4 at a location in front of the sensor unit 6 , the operator in Step 3 varies the distance 11 between the output lens 5 (and sensor element 9 ) and the products on the path 4 . While the operator varies the distance 11 , he or she also visually monitors the LED array 10 . Thus, in Step 4 when an LED corresponding to the known focal length becomes activated, indicating that the distance 11 is equal to that focal length, the operator ceases moving the laser head 1 , and fixes it in position. Depending upon whether the product is stationarily or periodically placed during this process, the appropriate LED will light in either a constant or periodic manner. After performing the process depicted in FIG. 2, the laser output lens 5 will be properly located at a distance equal to its focal length from products 2 which pass along the product path 4 .
The schematic of FIG. 3 depicts a calibrated window comparator circuit usable in an embodiment of the invention to activate a given LED in the array 10 when the distance 11 corresponds to the distance indicated by that LED. In this embodiment, one circuit according to FIG. 3 is used for each LED to be lit. The circuit depicted in FIG. 3 is calibrated to indicate a distance of 2.5″. One skilled in the art will appreciate how different resistor values may be used in the circuit to calibrate the circuit to respond to the same or different sensed voltages and thus the same or different desired distances. The circuit may be independently powered, or may be powered by the laser marking apparatus via an auxiliary port. The example in FIG. 3 receives power at an input 200 from the laser marking apparatus.
Although the particular selection and arrangement of elements is not critical, the sensor processor of FIG. 3 is constructed as follows: Resistors 250 , 252 , 254 , 256 , 258 , and 226 have values respectively of 6.34 k, 316, 8.25 k, 316, 1.8 k, and 1.8 k ohms. Capacitor 220 has a value of 0.1 microfarads. These values are not critical. For example, a variance of the values of resistors 250 and 252 without changing their ratios will not affect the operation of the circuit. Similarly, a variance of the values of resistors 254 and 256 without changing their ratios will not substantially affect the operation of the circuit, although it may affect the power consumption of the system. The values of resistors 258 and 226 may also be varied without substantially affecting the operation of the circuit. Capacitor 220 may be replaced by a slightly smaller or larger capacitor without substantially affecting the operation of the circuit.
A positive voltage, in this case 15V, is applied at input 200 via line 260 to the supply voltage inputs on comparators 202 and 204 , and to a first terminal of resistor 254 , and to a first terminal of resistor 250 , and to a first terminal of resistor 258 , and to a first terminal of capacitor 220 . The comparators may be built from standard op-amps such as those contained in the LM324A low power quad operational amplifier IC produced by SGS-Thomson Microelectronics, or may be built from separate transistors, other op-amps, or specialized comparator circuits. A second terminal of resistor 254 is connected via line 268 to a first terminal of resistor 256 and to the positive input of comparator 202 . A second terminal of resistor 250 is connected via line 264 to a first terminal of resistor 252 and to the negative input of comparator 204 . A second terminal of resistor 258 is connected via line 262 to the collector of transistor 212 and to the anode of LED 214 . LED 214 may be any LED, such as the Radio Shack catalog number 276-0004 LED, or any other device which lights when a voltage is applied across it. Transistor 212 may be any transistor, such as the Motorola MMBT2222L, which acts in substantially the same way, or any other device which provides the same function within the circuit. Ground is connected via line 266 to a second terminal of resistor 256 , to a second terminal of resistor 252 , to the emitter of transistor 212 , and to the cathode of LED 214 , and via line 270 to the ground supply inputs of comparators 202 and 204 , and via line 272 to a second terminal of capacitor 220 . An analog input signal from the sensor 9 of FIG. 1 is applied via line 206 to the positive input of comparator 204 and to the negative input of comparator 202 . The output of comparator 204 is connected via line 276 to the anode of diode 224 . The output of comparator 202 is connected via line 274 to the anode of diode 222 . The cathode of diode 224 is connected via line 278 to a first terminal of resistor 226 . The cathode of diode 222 is connected via line 278 to the first terminal of resistor 226 . A second terminal of resistor 226 is connected via line 280 to the base of transistor 212 . Diodes 222 and 224 may be the BAV70 high capacitance diode sold by Fairchild Semiconductor, or any other element which operates in substantially the same manner, by allowing current to flow substantially in one direction only.
The comparators 202 and 204 have threshold values set by the resistors 250 , 252 , 254 , and 256 . Using resistors of 6.34 k, 316, 8.25 k, and 316 ohms respectively for 250 , 252 , 254 , and 256 results in thresholds of about 0.55V and 0.7V for comparators 202 and 204 . This is dependent on the supply voltage, which is 15V in this embodiment. For the Hyde Park SM606A-BOB-00, the analog output for a sensed distance of 2.5″ falls between 0.55V and 0.7V. Accordingly, when the input 206 receives this voltage, the outputs of comparators 202 and 204 on lines 274 and 276 respectively, are low. This results in transistor 212 acting essentially as an open circuit, allowing LED 214 to be energized.
When the analog output of the sensor element 9 falls outside of this voltage window, the output of comparator 202 or comparator 204 will be high. This will cause transistor 212 to act essentially as a short circuit, pulling the potential on line 262 down to approximately zero volts. Accordingly, LED 214 will not be lit. It can be seen that several such circuits tuned to different voltage windows, and connected in parallel to the analog output of the sensor element 9 , will allow several LED's to be selectively activated depending upon the distance 11 measured by the sensor element 9 . Thus, a given distance 11 in FIG. 1 will result in a given analog output of the sensor element 9 , causing the LED whose comparator circuit window includes that particular voltage to be lit.
In an alternative embodiment, the top comparator 204 may be switchably or permanently disabled (output low) or eliminated entirely. This would result in each LED remaining lit as long as the sensor output was higher than its threshold setting. Thus, instead of one LED being lit at a given distance 11 , all of the LED's up to the most recently triggered LED would be lit.
In an alternative embodiment, the sensor processor circuits are instead connected to provide a control signal to an actuator 418 which is drivably connected to the movable laser output 402 as shown in FIG. 4 to facilitate adjusting the distance between the laser output 402 and a product to be marked 422 . In particular, similarly to the previous embodiment, the distance sensor 400 is preferably stationarily mounted with respect to the movable laser output 402 , such that the distance sensed by the sensor corresponds to the distance between the laser output 402 and the product 422 positioned along the product path 404 in front of the laser output 402 . The sensor processors 406 , 408 , 410 , 412 , 420 receive a signal output from the sensor 400 and preferably each supplies a sensor processor control output responsive to a different turn-on signal value corresponding to a particular distance between the laser output 402 and the product 422 .
A signal sensor circuit 424 contains the sensor processors 406 , 408 , 410 , 412 , 420 , and a mechanism such as multiplexer 414 communicatively connected via a control input 426 to selection mechanism 416 . The sensor processor control outputs of the sensor processors 406 , 408 , 410 , 412 , 420 may be multiplexed by the multiplexer 414 responsive to the selection mechanism 416 , or otherwise, such that the actuator 418 receives from the signal sensor circuit 424 a distance control output corresponding to a selected sensor processor circuit. In response to the received distance control output, the actuator 418 causes the movable laser output 402 to move relative to the product path 404 , and to stop when the control output indicates that the signal output of the sensor 400 has reached the turn-on signal value of the selected sensor processor circuit. In such an embodiment, the sensor processor circuits 406 , 408 , 410 , 412 , 420 may still, but need not, provide a human-perceivable indication of the sensed distance. The selection mechanism 416 may be manually operable by an operator. Alternatively, the selection mechanism 416 may be automatically operated responsive to the detection and identification of a particular output lens being utilized, via coded contacts or other measures well known to those of skill in the art.
Those skilled in the art will readily appreciate that the above-described circuits may be modified by substituting other circuit elements for those specifically identified, or by constructing different circuits to serve the same purpose, and to obtain a substantial equivalents. In view of the many possible embodiments to which the principles of this invention may be applied in view of the disclosed embodiments, it should be recognized that the embodiments described herein with respect to the drawing figures are meant to be illustrative only and should not be taken as limiting the scope of invention. For example, those of skill in the art will recognize that human-perceivable indicators other than LED's or the particular configuration of LED's disclosed may be used to implement the invention. An audio signal may be provided in lieu of or in addition to the visual indicator. Such an audio signal could be for example a synthesized or pre-recorded voice, or a tone. Furthermore, the circuitry shown is not critical to the invention. For example, a delay circuit may be included so that in operation the LED corresponding to the current sensed distance stays lit, without flashing on and off, until a product distance that differs by a substantial amount is detected for a certain period of time. The illustrated embodiment can be further modified in arrangement and detail by those skilled in the art in view of the present teachings without departing from the spirit of the invention. Therefore, the scope of the invention as described herein contemplates all such embodiments as may come within the scope of the following claims and equivalents thereof to the fullest extent permitted by law. | An improved laser marking focal length setting device allows an operator of a laser marking apparatus to easily and properly set the distance between a movable laser source output and an item to be marked. The device includes a sensor which is mounted at the same distance from the item to be marked as the laser source output. The device further includes an array of light emitting diodes, each of which corresponds to a predetermined focal length. In operation, the laser source output and sensor are moved together along the axis of the laser beam. The sensor supplies a signal indicative of the distance between the sensor and item. Because the laser source output and sensor are located at the same distance from the item to be marked, this signal is also indicative of the distance from the laser source output to the item. When the distance sensed is a focal length corresponding to one of the LED's, that LED lights. When the lit LED corresponds to the focal length of the current output lens, the operator may fix the output in its current position. Alternatively, the output is drivably connected to a motor, which is responsive to the sensor to drive the output to one of a plurality of predetermined distances. | 1 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to tendon tensioning anchor assemblies, and more particularly to improvements in sealing post-tension anchor assemblies to protect the exposed portions of a tendon from corrosion.
2. Description of the Prior Art
Conventional concrete reinforcing using tendons for stressing typically includes a pair of anchor assemblies mounted in spaced apart relation with an elongated reinforcing tendon extending therebetween. The tendon is placed under an axial load, either by pretensioning or post-tensioning, and connected to the concrete in the tensioned condition by the anchor assemblies. Tensioning of the tendon after the formation and setting of the concrete structure is known as post-tensioning and is widely used in the construction of prestressed concrete structures.
In the course of installing a tendon tensioning anchor assembly in a concrete structure, a hydraulic jack or the like is releasably attached to an exposed extending end of the tendon to apply a predetermined amount of tension to the tendon. The sheath, within which the remainder of the tendon is enclosed, protects against moisture and isolates the tendon from the surrounding concrete to facilitate the movement of the tendon relative to the surrounding concrete. When the desired amount of tension is applied to the tendon, wedges, threaded nuts or the like are used to connect the tendon to the anchor to hold the tendon in a stressed condition. After tensioning, the recessed ends of the tendon are cut off at the anchor by use of a cutting torch or the like.
Moisture travels through concrete. Concrete structures are frequently exposed to corrosive elements, such as de-icing chemicals, sea water, salt air or brackish water. In some environments, ground, water, run-off, snow and the like can immerse portions of the slab for substantial periods of time. The exposed ends of tendons from which the waterproof sheath has been stripped for tensioning can represent a substantial potential corrosion problem. Unless sealed against moisture, the exposed portions of the tendon are likely to suffer corrosion. This not only weakening the tendon, but the by-products of the corrosive reaction can fracture the surrounding structure.
One method of protecting tendons is disclosed in U.S. Pat. No. 4,348,844 issued to Schupack et al on Sept. 14, 1982. According to the teachings of this patent, the entire anchor assembly is enclosed in a housing or envelope. The use of a housing enclosing the entire anchor assembly is unduly expensive and is subject to damage during the cutting of the exposed recessed tendon end by use of a cutting torch. Installation of the housing as a separate unit apart from the anchor plate assembly, is time consuming and costly. This increased cost is unnecessary because there is no need to protect the entire anchor plate assembly from corrosion so long as the tendon itself is protected. Further, this assembly relies on plastic threads to form the seal. The manufacturing tolerances, dirty environment, distortion from heat and potential for stress deformation can result in a less than a reliable seal arrangement. Other examples of anchor assemblies using unreliable pleastic thread seals and/or multiple parts are shown in U.S. Pat. Nos. 4,616,458, 4,343,122, 3,956,797 and 3,820,832 and the U.S. and foreign patents cited in these U.S. patents.
The U.S. Pat. No. 3,596,330, to Scott, discloses another method which uses a deformable plug pushed into place to form a seal. However, no means are provided for positively locking the seal in position to prevent it from being dislodged during grouting.
SUMMARY OF THE INVENTION
The present invention provides a reliable sealed anchor assembly which is simple and inexpensive to manufacture and install.
In accordance with the invention, an anchor body is provided for anchoring a tendon in a concrete slab. The anchor body cooperates with and engages a removable seal carrying cap to provide a positive seal therebetween to prevent the entrance of moisture into the interior of the anchor body. The cap locks in place to compress a trapezoidal cross-section shaped seal ring between two nonparallel seal surfaces on the body and cap to ensure a positive seal. At least one surface of the seal ring is provided with a protrusion to improve sealing against the anchor body.
The anchor body has a base plate for fixing the anchor body in place. A tubular portion for receiving the tendon therein extends from the base plate. Locking means cooperate with the anchor body for releasably connecting the tendon to the body after the tendon has been tensioned. A locking recess is formed on the interior of the tubular portion for engaging locking fingers on the cap to positively attach the cap to the anchor body. A seal ring carrying portion is formed on the cap to position the seal ring to engage a first seal surface on the cap and second seal engaging surface on the end of the tubular portion whereby the seal can be compressed therebetween.
This assembly utilizes a minimum of parts and provides a positive seal for use in a dirty environment whose integrity is independent of stress distortion, the destructive presence of heat in cutting off the exposed tendon ends and manufacturing tolerances.
DESCRIPTION OF THE DRAWINGS
The objects, features and advantages of the present invention will become apparent from the following detailed description of the invention and accompanying drawings in which:
FIG. 1 is an exploded sectional view of the anchor assembly according to the present invention;
FIG. 2 is a sectional view of the anchor assembly of FIG. 1;
FIG. 3 is a perspective view of the anchor body and cap of the present invention;
FIG. 4 is an enlarged cross-sectional view of a resilient seal ring; and
FIG. 5 is an enlarged cross-sectional view of the cap and resilient seal installed on an anchor body.
DETAILED DESCRIPTION OF THE INVENTION
Referring to the drawings where like reference characters designate like or corresponding parts throughout the various figures, there is shown the improved anchor assembly of the the present invention which, for purposes of description, is designated by reference numeral 30. The anchor assembly 30 includes an anchor body 10, a sealing cap 11, a resilient annular seal 12, and a tubular trumpet member 13. Anchor body 10 can be formed from metallic material in a casting process. As a consequence of this manufacturing process, the surfaces of the body 10 can be rough and irregular. The body 10 has a tubular portion 21 with an external wall 32, a tendon receiving aperture 22 and a substantially larger diameter rear aperture 24 connected by a tapered central bore 26. Tapered central bore 26 is provided with a countersink 33 adjacent to the receiving aperture 22 for facilitating insertion of a tendon "T".
As shown in detail in FIG. 1 within the central bore 26 is formed an annular recess 27 located adjacent the aperture 24. Recess 27 forms a locking shoulder whose function will be hereinafter described in detail. Defining aperture 24 and extending radially to the external wall 32 of the tubular member 21 is a compound surface rim 20. Rim 20 comprises an annular seal engaging surface 28, and a cap mating shoulder 29. Surface 28 surrounds the rear aperture 24 and is aligned transverse to length of tubular portion 21. The cap mating shoulder 29 extends between surface 28 and the external wall of the tubular member 21. Shoulder 29 is outwardly inclined relative to the annular seal engaging surface 28.
As shown in FIGS. 1 and 3, extending outwardly from the external wall 32 of the tubular member 21 is a mounting flange 23 which is substantially planer and is aligned transverse to the length of member 21. Flange 23 is provided with a plurality of holes 36 and 37 for permitting the temporary attachment of the anchor body 10 to form members while pouring and hardening of the surrounding concrete. Extending outwardly from the external wall 32 of the tubular member 22 and connected to the mounting flange 23 are reinforcing ribs 34 and 35.
As shown in FIGS. 3 and 5, sealing cap 11 has a central cavity 17. A receiving collar 19 provides a close telescoping fit over and around the tubular member 21 such that in the assembled condition, the inside wall 16 of the receiving collar 19, engages the external wall 32 of the tubular member 21 to help properly align the cap 11 in position. Within cavity 17, is provided an annular frusto-conical sealing surface 18 correspondingly inclined to mate with shoulder 29 when the cap 11 is position as shown in FIG. 5.
A plurality of circumferentially spaced resilient locking fingers 15 provide a means for securing the sealing cap 11 to the tubular member 21. The locking fingers 15 being engagable with the shoulder in annular recess 27.
In the preferred embodiment, a plurality of guide fingers (not shown) are positioned between the locking fingers 15. Guide fingers are adapted to telescope in a close fitting arrangement into bore 26. Within the cylindrical space defined by the locking fingers 15 and the guide fingers, there is defined a chamber for the severed end of a tendon "T".
In the preferred embodiment, seal 12, is positioned within the central cavity 17 of the sealing cup 11, contacting the annular frusto-conical sealing surface 18 and closely fitted around the circular formation of locking fingers 15 and the guide fingers. The resilient annular seal 12, best illustrated in FIG. 4, has a trapezoidal cross-section shape. Seal ring 12 has generally cylindrical inner and outer surfaces 12a and 12b which intersect non-parallel faces 12c and 12d. Face 12c is preferably inclined at an angle "A" of, for example, twenty degrees relative to face 12d. To facilitate forming a seal against annular seal engaging surface 28, an annular projection or bead 12e is formed to extend from face 12d intermediate inner and outer surfaces 12a and 12b. Bead 12e has a small radius, for example, 3/64th inch if face 12d is 0.40 inch, to provide a ring of increased bearing pressure to facilitate deformation of bead 12e such that resilient material flows and deforms to seal against roughened portions of surface 28.
The shape of seal ring 12 permits a frusto-conical mating between seal and the frusto-conical sealing surface 18 when the cap 11 is in place. The trapezoidal configuration of the resilient annular seal 12 permits a watertight seal having a range of sealing integrity substantially greater than that of a conventional O-ring seal. This range responds to potential variations in axial distance between the annular frusto-conical sealing surface 18 of the sealing cap 11 and the annular seal engaging surface 28. These variations in axial distance being frequently encountered in the process of mass production of mating components.
Trumpet member 13 has a central bore corresponding to the tendon axis, enshrouds the receiving aperture 22 of the tubular member 21 and can be conventionally sealed to the tendon "T".
In use, once the anchor body 10 has been set in concrete "C" in a recessed position as shown in FIG. 2, the tendon "T" can be engaged and tensioned in a conventional manner. Tensioned locks or wedges "W" are used to lock the tendon to the anchor. The extending end of the tendon can be cut off using a cutting torch or the like. Use of a cutting torch allows the tendon to be quickly cut off in the recess so that the end is flush with the upper surface of the anchor body 10. During this cutting process, any exposed plastic parts of the anchor sealing assembly would be exposed to destructive heat. As can be seen in the present invention, no plastic parts or threads are exposed to the intense heat of the cable cutting process. Once the cable is cut, the sealing cap 11 is pushed into the locked sealing position shown in FIG. 5.
the embodiment shown and described in this application is but one embodiment for accomplishing applicant's invention. It is to be understood that the present invention shall include all embodiments of the invention as defined in the accompanying claims. | A protective tendon tensioning anchor assembly comprising an anchor plate, a sealing cup and a resilient sealing ring for providing corrosion protection for exposed portions of a tendon secured in the tendon tensioning anchor assembly. | 4 |
BACKGROUND OF THE INVENTION
This invention relates in general to low surface energy fluoropolymers and more specifically to fluorinated polyurethanes which are the condensation products of fluorinated tertiary polyfunctional alcohols and aliphatic diisocyanates.
Perfluorinated polymers have long been employed as low surface energy coatings and materials. These polymers, despite their relatively high costs, have found uses in O-rings, gaskets, diaphragms, fuel tank sealants, and coatings. The high cost of these polymers, however, has limited the use of these polymers to relatively expensive items. Much of this cost may be attributed to the expense of perfluorination. A low surface energy polymer which is not highly fluorinated would eliminate much of this expense.
The isocyanates, containing the highly unsaturated --N═C═O group, are highly reactive with a host of compounds and may also react with themselves. Reaction can occur with almost any compound possessing a hydrogen atom that may be replaced by sodium and can occur with a few other compounds having hydrogen atoms not readily replaced by sodium. In such a reaction, the hydrogen becomes attached to the nitrogen of the isocyanate and the remainder of the active hydrogen compound becomes attached to the carbonyl carbon:
R--N═C═O+HOR→RNHCOOR
In many cases this addition product is quite stable. In special cases the addition product is only moderately stable and may decompose to form the initial reactant again or may decompose to other products.
In most reactions, especially with active hydrogen compounds, the aromatic isocyanates are more reactive than are the aliphatic isocyanates. In addition, substitution of electronegative groups on the aromatic ring enhances the reactivity whereas electropositive groups reduce the reactivity of the isocyanate. As would be expected, steric hindrance on either the isocyanate or the active hydrogen compound will retard the reaction. All of the reactions are subject to catalysis by acids and by bases; certain metal compounds are exceptionally powerful catalysts. In light of the great variety of reactions possible, it is fortunate that conditions which permit highly selective control of the reactions actually occurring can usually be chosen. It is this wide range of reactions possible, plus the host of reactive materials available, combined with good control of the desired reactions that permit one to tailor make a variety of polymers.
Although most urethane coating systems are largely based on aromatic diisocyanates due to their excellent properties, they typically exhibit poor color stability when exposed to ultraviolet radiation. Additives improve their performance, but only delay the color change. It has been shown that by using aliphatic diisocyanates in place of aromatic diisocyanates such as toluene diisocyanates, polyurethane coatings with outstanding light stability could be produced. Hexamethylene diisocyanate has been used for many years in experimental programs. However, owing to its high vapor pressure, a polyisocyanate of biuret structure based on hexamethylene diisocyanate is used commercially. This compound is produced from the reaction of the diisocyanate with water. This polyisocyanate: ##STR1## still retains the aliphatic characteristics desirable for a nonyellowing coating and also has a very low vapor pressure, thus reducing the hazards of unmodified hexamethylene diisocyanate.
OBJECTS OF THE INVENTION
It is a principal object of this invention to provide a new class of fluorinated polyurethanes.
It is another object of this invention to produce a new class of fluorinated polyurethanes having exceptional heat, light, and chemical resistance and a low surface energy.
It is a further object of this invention to produce fluorinated polyurethane prepolymers from a fluorinated tertiary polyfunctional alcohol and an aliphatic diisocyanate.
It is yet another object of this invention is to provide new fluorinated polyurethane prepolymers terminated with both diisocyanate and dihydroxyl groups.
It is a still further object of this invention to provide low surface energy fluorinated polyurethane resins at a reduced cost.
SUMMARY OF THE INVENTION
These and other objects are achieved by reacting a fluorinated tertiary polyfunctional alcohol with an aliphatic diisocyanate in the presence of a polyurethane-forming catalyst.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The tertiary fluorinated polyfunctional alcohols employed in this invention typically have the structure: ##STR2## wherein R is any branched or unbranched, saturated or unsaturated aromatic or aliphatic hydrocarbon di- or tri-radical; w, x, y and z are integers from 0-10 and may be the same or different; L represents --H, ##STR3## or --(CF 2 ) v CF 3 where u and v are integers from 0 to 10 and may be the same or different.
Preferably, R is a meta- or para-substituted benzene diradical or a benzene triradical. Most preferably, R is a meta- or para-substituted benzene diradical. Preferably, w, x, y and z are the same. Most preferably, w, x, y and z are 0. Preferably, u and v are the same. More preferably, u and v are 0. Most preferably L is --H.
Examples of useful aromatic alcohol reactants are 1,3-bis (2-hydroxyhexafluoro-2-propyl)benzene, 1,4-bis(2-hydroxyhexafluoro-2-propyl)benzene and 1,3,5 tris(2-hydroxyhexafluoro-2-propyl)benzene and mixtures thereof. Often, commercially available preparations of the 1,3 bis alcohol include some of the 1,4 bis compound as well, typically about 10 weight percent. This impurity is of little consequence, and the 1,3 bis compound need not be further purified to give consistent results. If the tris compound is used, cross-linking will occur, resulting in a polymer which is insoluble in common organic solvents, such as methylene chloride.
The diisocyanates employed in this invention typically have the structure:
OCN--R.sub.a --NCO
where R represents a fluorinated or unfluorinated aliphatic (alkylene or alkylenylene) diradical having no fluorinated carbons adjacent to the isocyanate groups or any cycloaliphatic hydrocarbon diradical such as cyclopentylene and cyclohexylene. Preferably, R a is an aliphatic hydrocarbon diradical having 2 to 8 carbons or a cycloaliphatic diradical. Most preferably R a is an aliphatic having 6 carbons. R a is preferably unfluorinated. The biuret derivative of the diisocyanates may also be employed where a cross-linked polymer or prepolymer is desired.
To produce polyurethanes having a relatively high average molecular weight, several factors must be taken into account. First of all, the condensation reaction must be specific and must take place in high yield. Furthermore, high purity is essential if high molecular weight linear polyurethanes are to be obtained. Monofunctional impurities would act as stoppers, thereby resulting in low molecular weight polymers. The reactant balance would also be upset by the presence of water. Essentially equimolar quantities of the diisocyanate and alcohol must be used to obtain high molecular weight, linear polyurethanes. Excess diisocyanate appears to be less harmful than excess alcohol. This apparently is due to the many potential side reactions which can occur to consume excess diisocyanate. Reaction times of 1-2 hours were found necessary to obtain high molecular weight polyurethanes. Long term heating, however, often resulted in degradation of the polyurethanes. If these requirements are not totally met, then lower to moderate molecular weight polyurethanes will be obtained.
The novel fluorinated polyurethanes of the present invention are generally prepared by reacting approximately stoichiometric ratios of the fluorinated tertiary alcohol and an aliphatic diisocyanate. In order to obtain a tough polymer, the temperature of the reaction medium must exceed 80° C. for an extended period. Since the resulting clear polyurethane is insoluble in common organic solvents, it is not known whether crosslinking occurs through a secondary reaction of the isocyanate group with the urethane N--H groups and/or through hydrogen bonding involving the urethane N--H and C═O groups.
This invention also includes the formation of prepolymers for use as coatings or adhesives. Isocyanate-terminated prepolymers can be prepared by using a molar excess of diisocyanate. This prepolymer can be subsequently advanced with active hydrogen containing compounds such as diamines, diols, dithiols, etc. Hydroxyl-terminated prepolymers can be prepared by using a molar excess of alcohol. This prepolymer can be subsequently advanced with additional diisocyanate.
The synthetic scheme is shown below: ##STR4## wherein r is an arbitrarily large integer and s and t are integers less than r and dependent upon the relative ratios of the reactants. Typically, s and t are between 1 and 100. Most preferably s and t are between 1 and 15.
In the present invention, the polyurethanes are prepared by the reaction of a diisocyanate with a fluorinated tertiary polyfunctional alcohol in the neat state under an inert atmosphere. A polyurethane-forming catalyst (defined as a catalyst commonly used to catalyze polymerization reactions between alcohols and diisocyanates, e.g., dibutyltin dilaurate and 1,4-diazobicyclo (2.2.2) octane (also known as Dabco™)) should be present during the reaction. If a prepolymer is desired, careful control of the polymerization is necessary in order to avoid crosslinking resulting in an insoluble polymer product. Typically, the reaction is run at 50°-150° C., preferably at 50°-80° C. and most preferably at 50°-70° C. for the polyurethane prepolymers. When stoichiometric ratios of the reactants are interacted, higher temperatures are typically required to ensure complete reaction. The resulting clear polyurethanes are tough, rubbery, and insoluble in common organic solvents, indicative probably of hydrogen bonding of the urethane N--H and C═O groups and/or crosslinking involving the urethane N--H groups and the isocyanate groups.
In this specification and the claims that follow, the term "stoichiometric ratio" refers to a ratio of reactants which, when reacted according to the process disclosed herein for synthesizing polyurethane polymers yields a polymer which is insoluble in methylene chloride. The term "non-stoichiometric ratio" or a specified molar excess of a reactant refers to a ratio of reactants which when reacted according to the process disclosed herein for synthesizing non-crosslinking polyurethane prepolymers yields a prepolymer which is soluble in methylene chloride.
The new fluorinated polymers and prepolymers exhibit good wetting properties and the prepolymers adhere strongly to Teflon™. Because the novel polymers need not be highly fluorinated but need only contain trifluoromethyl groups (on at least 2 alcoholic carbons), these polymers are much cheaper to produce than standard fluorinated acrylics.
EXAMPLES
Having described the invention in general, the following examples are being given to illustrate the principles of the invention and are not intended to limit the scope of the invention in any manner.
Example 1
1,3-Bis(2-hydroxyhexafluoro-2-propyl) benzene (0.505 g, 1.23 mmol), 1,6-hexamethylene diisocyanate (0.209 g, 1.24 mmol), and 2 drops of dibutyltin dilaurate were weighed into a 5 ml flask and heated at 50° C. for 24 hours and at 75° C. for 24 hours under a dry nitrogen atmosphere. A small quantity of the clear, brittle solid was dissolved in 2-butanone (MEK) and concentrated onto an NaCl infrared disk. An infrared spectrum of the resulting film showed a small absorption at 2275 cm -1 indicating the incomplete reaction of the isocyanate group. No further change in the infrared spectrum was observed upon further heating of the sample at 75° C. A number average molecular weight, M n , of 2536 as determined by Vapor Phase Osmometry confirms the incomplete reaction and the formation of low molecular weight polyurethanes. The reaction mixture was then heated at 90° C. for 24 hours. Upon examination of product mixture at 90° C., the polymer was soft and rubbery. When cooled, the fluorinated polyurethane was tough and somewhat flexible. Moreover, the polyurethane was now insoluble in ethyl acetate, 2-butanone, methylene chloride, acetone and other common organic solvents, indicating probably that some type of crosslinking had occurred.
Example 2
Using the method of Example 1, 1,3-bis (2-hydroxyhexafluoro-2-propyl) benzene (0.506 g, 1.23 mmol), 1,6-hexamethylene diisocyanate (0.207 g, 1.24 mmol), and 2 drops of dibutyltin dilaurate were weighed into a 5 ml flask and heated at 45° C. for 24 hours and at 75° C. for 24 hours under a dry nitrogen atmosphere. The clear, brittle solid was then heated at 80° C. for 8 hours. The sample now appeared tougher and somewhat rubbery. An extremely weak absorption at 2275 cm -1 indicated that some isocyanate groups were still present. Moreover, the clear polymer was not only partially soluble in common organic solvents. The sample was then heated at 90° C. for 18 hours. The polyurethane was now completely insoluble in all organic solvents.
Example 3
1,3-Bis(2-hydroxyhexafluoro-2-propyl) benzene (1.997 g, 4.87 mmol), 1,6-hexamethylene diisocyanate (1.112 g, 6.62 mmol), and 2 drops of dibutyltin dilaurate were weighed into a 5 ml flask and heated at 50° C. for 24 hours and at 60° C. for 24 hours under a dry nitrogen atmosphere. The clear, brittle polyurethane prepolymer was soluble in common organic solvents. An infrared spectrum showed the absence of absorptions centered at 3600 and 3535 cm -1 , attributed to free and associated hydroxyl groups, respectively. Further heating at 75° C. for 8 hours did not cause any observed change in the intensity of the isocyanate (2275 cm -1 ) and carbonyl groups (1750 and 1690 cm -1 ). The number average molecular weight M n was 2257 as determined by Vapor Phase Osmometry.
Another sample of 1,3-bis (2-hydroxyhexafluoro-2-propyl) benzene (1.002 g, 2.44 mmol), 1,6-hexamethylene diisocyanate (0.546 g, 3.25 mmol), and 2 drops of dibutyltin dilaurate was given the same heat treatment as described above. The clear solid was soluble in common organic solvents. As determined from an infrared spectrum, the hydroxyl groups had been completely consumed. The fluorinated polyurethane prepolymer terminated by isocyanate groups was then heated at 85° C. for 24 hours. The prepolymer was now completely insoluble in common solvents indicating that some crosslinking had probably occurred.
Example 4
1,3-Bis (2-hydroxyhexafluoro-2-propyl) benzene (1.343 g, 3.28 mmol), 1,6-hexamethylene diisocyanate (0.408 g, 2.43 mmol), and 2 drops of dibutyltin dilaurate were weighed into a 5 ml flask and heated at 50° C. for 24 hours and at 65° C. for 24 hours under a nitrogen atmosphere. The polyurethane prepolymer terminated by hydroxyl groups was soluble in common organic solvents. The number average molecular weight, M n , was 2015 as determined by Vapor Phase Osmometry.
Obviously many modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that, within the scope of the appended claims, the invention may be practiced otherwise than as specifically described. | Novel polymers and prepolymers are formed by reacting a fluorinated terti polyfunctional alcohol with an aliphatic diisocyanate or a biuret derivative of said diisocyanate in the presence of a suitable catalyst and in the absence of solvent. The novel polymers and prepolymers exhibit low surface energy properties and may be used in non-fouling coatings, foams and elastomers. | 2 |
This is a continuation of application Ser. No. 07/952,875, filed as PCT/SE/00346 May 16, 1991, now U.S. Pat. No. 5,352,333.
TECHNICAL FIELD
The present invention relates to a process for partial combustion of cellulose spent liquors from the cellulose industry using a burner connected to a reactor, while supplying an oxygen containing gas as the oxidant. The burner comprises a liquor lance equipped with a nozzle at its downstream end which supplies liquor and the greater part of the non-fuel related oxygen required for the partial combustion, wherein or in which proximity the oxygen-containing gas is brought into contact with the spent liquor which then disintegrates into a divergent spray.
The object of the present invention is to facilitate partial combustion of cellulose spent liquor through use of a burner creating a stable, self-igniting flame at low air/fuel ratios and elevated pressures.
BACKGROUND OF THE INVENTION
The cellulose industry generates spent liquors differing in composition according to the delignification process used. Within the sulphate pulping industry, spent liquor, commonly referred to as black liquor, contains valuable chemicals and energy in the form of combustible carbonaceous compounds. At the present time these chemicals and energy are normally recovered in a recovery boiler in which the black liquor is completely burned.
Partial combustion of black liquor in a gasification reactor as in the present invention generates a combustible gas comprising H 2 , CO, CO 2 , and droplets of molten inorganic chemicals.
In conjunction with pulp bleaching, a diluted liquor comprising organic matter and sodium salts is obtained. Mechanical and semi-chemical pulping processes also generate diluted liquors of different compositions. These as well as other waste and spent liquors generated in the cellulose industry can, after concentration, be used as a feedstock in the process of the present invention.
Although the following description describes the present invention as it applies to black liquor it is not restricted only to this particular liquor in its application.
The mechanisms related to partial combustion of black liquor are fairly well understood and are applied inter alia in the lower part of the soda recovery boiler. The difference between the present burner and a liquor burner in a soda recovery boiler is, however, great inter alia due to the low degree of liquor atomization in recovery boiler burners and the absence of a well-defined liquor flame. Another important difference between a recovery boiler burner and the burner of the present invention is that, the present burner is primarily intended for gasification at elevated pressures.
A major difference between the burner of the present invention and conventional oil burners is that a stable flame has to be formed with the use of a considerably lower amount of air or oxygen carrier.
As the exemplification below shows, black liquor as a fuel is characterized by a relatively low calorific value and high water and ash contents.
______________________________________Calorific value of 13 GJ/ton dry substance (DS)the dry substanceElementary composition C.sub.29 H.sub.34 O.sub.20 Na.sub.9 S.sub.2Dry solids content 65%Viscosity at 100° C. 100 cSt.______________________________________
The presence of sodium compounds in the black liquor and its inherently high oxygen content make it a very reactive fuel, which means, provided an adequate burner is at hand, that the carbon conversion already in the flame zone becomes high, in spite of the fact that the combustion is substoichiometric.
The degree of atomization of the liquor is of great importance for obtaining a stable black liquor flame, the extension of the flame and high carbon conversion. The rheological properties of the black liquor are of significant importance to the degree of atomization which can be achieved in a given nozzle. The viscosity of the black liquor can be influenced by e.g. heating and/or the addition of additives. Normally the black liquor is being heated to above 100° C. for use in the present invention. The viscosity of the black liquor at the the moment of atomization should preferably be below 200 cSt.
Atomization of the black liquor can be further enhanced by flashing the liquor into the reactor in which case the liquor is preheated to a temperature above its boiling point at the operating pressure of the reactor.
Several types of atomizing nozzles are available but only a few varieties are suitable for atomizing cellulose spent liquors, such as black liquor, in the present invention.
"Twin-fluid" nozzles are most suitable for use in the present burner. A common feature of "twin-fluid" nozzles is that a relatively high gas flow rate is necessary for the supply of energy for the atomization. Another important feature of these nozzles is that the resulting size of the droplets decrease with increasing density of the atomizing gas. Depending on how the two fluid phases are brought together several mechanisms for forming droplets, such as shearing between ligaments, combination and formation of spheres of liquor droplets and high turbulence decomposition of the liquor spray can be anticipated.
DESCRIPTION OF THE PRESENT INVENTION
The present invention describes a process for efficient substoichiometric combustion of cellulose spent liquors, using a burner connected to a reactor, while supplying an oxygen containing gas, which invention is characterized in that the weight ratio between the oxygen containing gas supplied through the burner and the spent liquor supplied through the burner is lower than 2:1, and that at least half of the oxygen which is required for the partial combustion of the spent liquor is supplied through the burner to the reactor as an oxygen containing gas, said gas being discharged into the reactor through the nozzle.
Efficient atomization of the spent liquor is particularly important and is achieved in the burner of the present invention by direct contact between the spent liquor and the oxygen containing gas at elevated pressure in or directly adjacent to a nozzle designed specifically for that purpose. The spent liquor, which should be preheated to lower the viscosity before being fed to the burner, is supplied to the reactor through the liquor lance. At the downstream end of the liquor lance the liquor is brought into contact with an atomizing gas whereby the liquor flow velocity rapidly increases resulting in the formation of a divergent spray of atomized spent liquor.
As is mentioned above the spent liquor is a fuel with unusual properties regarding reactivity and ash and water contents. The spent liquor solids contains a high level of bound oxygen which means that the amount of oxygen which can be supplied through the combustion air is relatively small, particularly for partial combustion.
The oxygen supplied to the reactor corresponds to a stoichiometric ratio of between 0.3 and 0.6 relative to oxygen required for complete combustion of the spent liquor with a preferred ratio of between 0.35 and 0.5. The amount of air, oxygen-enriched air or oxygen to be supplied to the reactor is low in relation to the amount of spent liquor supplied. The weight ratio is lower than 2:1 when operating with air as oxidant and lower than 0.4:1 when operating with oxygen as oxidant. The greater part, and preferably more than 80% of the non-fuel bound oxygen which is required for partial combustion of the spent liquor is supplied to the reactor as an oxygen containing gas, which gas is discharged together with the liquor through the nozzle. The flow velocity of the oxygen containing gas in the nozzle should be between 40 m/s and 350 m/s.
The nozzle can be designed with a circular gap or a circular opening for discharge of spent liquor, wherein it is contacted with the high velocity atomizing oxygen containing gas and disintegrates into small droplets forming of a divergent spray. In an alternative design of the nozzle the spent liquor is discharged together with the atomizing gas through three or more symmetrically arranged openings.
Other aspects and advantages of the invention become apparent from the following more detailed description, taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an axial sectional view of a first embodiment of the burner according to the invention comprising a nozzle and a liquor lance;
FIG. 2 is a sectional view of the burner of FIG. 1 along line III--III in FIG. 1;
FIG. 3 is an axial sectional view of a second embodiment of the burner according to the invention comprising a nozzle and a liquor lance; and
FIG. 4 is a sectional view of the burner of FIG. 3 along line V--V in FIG. 3.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The burner 1 according to the invention shown in FIGS. 1 and 2 comprises a twin-fluid, substantially cylindrical liquor lance 26 and a nozzle 8 in which black liquor and gas are mixed. Nozzle 8 has the form of a Y-jet atomizer head of about rotationally symmetric shape. Its front face 2 is substantially flat and has a number of circular openings 3 equidistantly arranged along its chamfered circumferential front edge. From each opening 3 a bore 34 in nozzle 8 extends obliquely in respect of nozzle axis 23 in a way as to make their axes meet at a point on axis 23 inside of burner 1.
At a distance from openings 3 each bore 34 splits into two channels designated 4 and 5 extending to the rear side of nozzle 8 which fits snugly to the liquor lance portion 26 of the burner in the way described below.
The main portion of the liquor lance comprises an outer cylindric wall 10, an intermediate cylindric wall 18 and an inner cylindric wall 19 defining between them concentric spaces 6 and 7, respectively, extending over the entire length of the lance. Toward the end of the liquor lance portion 26 facing the rear side of nozzle 8 the radial width of concentric spaces 6 and 7 is reduced to about that of bores 4 and 5 at their respective rear side ends. By this arrangement and by making the front side of the liquor lance portion 26 and the rear side of the atomizer nozzle 8 fit each other snugly communication between concentric spaces 6 and 7 and, respectively, bores r and 5 is obtained.
The atomizer nozzle 8 is held attached to the liquor lance portion 26 by an annular hood 9 fitted to outer liquor lance wall 10.
At its rear end nozzle 1 is provided with black liquor and air inlet tubes 20, 21 communicating with concentric spaces 6 and 7, respectively. Black liquor and air fed into nozzle 8 will mix at the Y-junction of the Y-jet atomizing nozzles and then be forced under high pressure through the symmetrically arranged circular openings 3.
FIGS. 3 and 4 show another embodiment of the burner 1' according to the invention having a liquor lance portion 26' with three concentric annular spaces 11 (outer), 12 (central), 13 (inner). Concentric spaces 11,12,13 are defined by cylindric walls 30,31 (11), 31,32 (12), and 32,33 (13). Through inlet pipes 20',21',22 arranged near the rear end of liquor lance portion 26', air (through pipes 21', 22) is fed into annular spaces 11 and 13, and black liquor (through pipe 20') is fed into annular space 12.
The burner 1' of FIGS. 3 and 4 instead of a separate atomizer head has a downstream frontal atomizer portion 8' integral with the liquor lance portion 26'. Near its downstream end annular space 12 narrows to form a circular gap 16 while outermost and innermost annular spaces 11, 13 merge with two sets of narrow bores 14 and 15, respectively, the eighteen bores of the respective sets being arranged equidistantly from nozzle axis 23' and evenly spaced from each other, as seen in the sectional view of FIG. 4. Gap 16 and bores 14,15 open at the front side 2' of the substantially cylindric nozzle portion 8'.
The frontal end portions of cylindric walls 30 and 31, respectively, are drawn inwardly in direction of axis 23' to form annular lips 17, 24. By lip 17 the black liquor fed through the narrow gap 16 as a thin film is forced inwards and atomized by meeting the air emerging from holes 15. This flow of primary air-black liquor mixture is met by additional air emerging from holes 14 and deflected inwards (towards the center axis of the nozzle) by lip 24, thereby creating a diverging jet of finely dispersed black liquor.
When designing burners great attention has to be paid to the weight ratio between oxidant and fuel.
Different fuels contain different amounts of chemically bound oxygen. Bitumenous coal usually contains between 4-10% of bound oxygen. Fuel oils contain less than 1% of bound oxygen.
Black liquor dry solids contains about 35% by weight of bound oxygen calculated on dry, matter. This affects the design of burners for combustion of black liquor since a considerably lower amount of oxygen, air or oxygen enriched air has to be added to the reactor to obtain the desired level of combustion.
The air/fuel ratio (by weight) for some fuels at stoichiometric combustion are exemplified below:
______________________________________Anthracite Air/fuel 10-12:1Ethyl alcohol Air/fuel 9:1Black liquor Air/fuel 4-5:1Diesel oil/heavy oil Air/fuel 13-15:1______________________________________
The burner designed in the present invention creates a stable flame in a reactor which preferably operates at pressures in the range of 0.1 to 150 bars above ambient and at temperatures in the range of 700° to 1400° C.
Depending on factors such as temperature and flow velocities in the burner and the composition of the liquor, the burner nozzle can in addition to thermal effects be subjected to oxidation and reactions with sulphur which may have a detrimental effect on the degree of atomization. The burner nozzle of the present invention should therefore preferably be cooled by a circulating liquid.
A preferred embodiment of the present invention is to use oxygen or oxygen enriched air as the oxidant. In such a preferred embodiment all or nearly all the the oxygen required for partial combustion is supplied through the nozzle to support atomization of the spent liquor.
Part of the oxygen containing gas may be added to the reactor through a pipe arranged coaxially around the liquor lance or through one or several gates. To compensate for the low air/fuel ratios and to achieve reasonable gas velocities all of the oxygen containing gas should be preheated to at least 100° C., preferably to 300° C., and it should further be given a vortex movement which, i.a., can be achieved by passing the gas through vortex blading arranged in the coaxial pipe. The radial flow rate of the oxygen containing gas is thereby markedly affected with a maintained axial flow rate. The main principle of a vortex burner is to recirculate a portion of gases through an internal recirculation zone towards the liquor lance. This internal recirculation zone facilitates combustion and stabilizes the frame and the recirculated hot gases add energy for ignition of the liquor spray. The internal recirculation zone also serves as a depot for heat and reactive gas components. | The present invention is directed to a process for efficient combustion of cellulose spent liquors using a burner connected to a reactor, while supplying an oxygen containing gas, which invention is characterized in that more than 80% of the oxygen which is required for the partial combustion of the spent liquor is supplied through the lance of the burner to the reactor as an oxygen containing gas at a stoichiometric ratio of between 0.3 and 0.6 relative to complete combustion of the spent liquor. | 2 |
TECHNICAL FIELD
This invention is related to unitary tubular gripping members for pivotal mounting on well tools to secure the well tool in place in the well casing.
BACKGROUND OF THE INVENTION
A well packer utilizing a tubular gripping member was first disclosed in U.S. Pat. No. 3,548,936 to Kilgore et al. The well packer gripping slip disclosed therein utilized a generally flat tooth profile along a substantially cylindrical surface.
One improvement in this gripping member involved providing versatility by varying the tooth crest diameter over several rows of teeth so the gripping member could be utilized in casing sizes of varying internal dimensions with improved gripability of the well packer gripping member therein.
Another improvement in the gripping member is directed to having a curved bounding tooth profile with varying angles of tooth faces according to the location of the tooth along the curved tooth profile to provide constant gripability in well casings.
SUMMARY OF THE INVENTION
This unitary gripping member has gripping surfaces formed by a plurality of insert teeth elements arranged in groupings to provide constant and positive gripability of the gripping member in the well casing. The insert teeth elements are placed in groupings such that outer or crest edge surfaces thereof outline a curved profile which uniformly engages the well casing upon rotation of the gripping member for setting the well tool with a minimum of slippage in the well casing. An object of this invention is to provide a unitary gripping member with a plurality of insert teeth elements which form the profile of gripping surfaces on the gripping member and which will easily, quickly and with a positive action dig into or grippingly engage the interior surface of a well casing for securing a well tool.
Another object of this invention is to provide a unitary gripping member or slip for a well tool having the gripping surface formed by by a plurality of individually inserted tooth elements that define a crest line by forming the profile of gripping surfaces and wherein these tooth elements are significantly harder than a typical well casing in which the tool is installed thus enhancing the gripping ability of the slip and permitting it to grip the casing easily and quickly without being damaged by longitudinal sliding movement in the casing.
Various other objects, advantages and features of this invention will become apparent to those skilled in the art from the following discussion taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-sectional side view of a tubular gripping member having the present invention;
FIG. 2 is a cross-section of the insert toothed portion of the gripping member of FIG. 1 taken on line 2--2 of FIG. 1; and
FIG. 3 is a perspective view of the tubular gripping member taken from the side having the plurality of insert teeth elements.
DETAILED DESCRIPTION
FIG. 1 is a full side cross-sectional view of a unitary anchor or tubular gripping member 10 (commonly referred to as a slip) having a generally cylindrical body with dual axis bore passage 12 longitudinally therethrough. Bore passage 12 comprises two intersecting cylindrical bores having axes X--X and Y--Y intersecting at point C. Point C is the axis of pivotal support for tubular gripping member 10. A series of parallel peripheral ridges 14 are formed along what normally is the lower end of one side of tubular gripping member 10 when installed. Ridges 14 define teeth on the load end of tubular gripping member 10. A diametrically opposed set of teeth, indicated generally at 16, are formed in what is normally the upper opposite side of the tubular gripping member. Teeth 16 are on the passive end of tubular gripping member 10.
Tubular gripping member 10 is adapted to be placed over a tubular mandrel having a general external diameter slightly smaller than the bore of bore passage X--X as shown by dimension A. Tubular gripping member 10 is adapted to partially rotate about point C on the tubular mandrel passing therethrough. The rotation of body member 10 serves to move both of the toothed sections 14 and 16 into and out of contact with the inner wall of a well casing. This rotation occurs when the well packer or other well tool upon which tubular gripping member 10 is set or is released.
When tubular gripping member 10 is oriented such that the bore passage corresponding to axis X--X is parallel to the packer mandrel, then the sets of teeth 14 and 16 will be in the non-contacting position in the casing. When tubular gripping member 10 has rotated toward a position where axis Y--Y approaches or is parallel to the packer mandrel, then teeth sets 14 and 16 will be moved outward into biting engagement in the casing interior.
Referring to FIGS. 1 and 2 together, such illustrates placement of some of the insert teeth in tubular gripping member 10. All of the individual insert teeth elements are secured in a similar manner. A recess including a curved side wall 18 having a substantially flat bottom portion 20 transverse to side wall 18 is formed in the external peripheral portion of the tubular gripping member side wall 18 has a substantially constant diameter curvature defined about a longitudinal axis which is angularly oriented relative to bore passage axis X--X. An insert tooth member 22 is positioned within the recess adjacent to bottom 20 and side wall 18 and secured in the position shown. Insert tooth 22 is a cylindrical member with the ends transverse to the cylindrical axis thereof. The diameter of insert tooth 22 is selected slightly smaller than the diameter of cylindrical side wall 18 so the tooth will fit snugly within the recess and a cutting tip portion thereof will extend from the recess and beyond the outer surface boundary of tubular gripping member 10 thereby forming a gripping surface of the tubular gripping member. Insert tooth 22 can be constructed of very hard metallic material such as an alloy containing a significant portion of carbide or other metallic alloys which are specially blended to be very hard as well as wear and abrasion resistent. One suitable tooth material is an alloy of tungsten carbide. The insert teeth can be secured in place in the respective recesses of tubular gripping member 10 by utilizing bonding techniques, welding or soldering. Where tungsten carbide insert tooth members have been used, they have successfully been retained in the recesses of tubular gripping member 10 by using a category of silver brazing alloys commonly referred to as "silver solder".
Referring to FIGS. 2 and 3, which cooperatively show the general arrangement, the insert teeth elements in their relative location on the exterior of tubular gripping member 10. The plurality insert teeth are positioned so that the crests thereof define a crest line curing around the exterior of tubular gripping member 10. In FIG. 3, these crest lines indicated by fine dashed lines drawn through the crest of the teeth and indicated at 24, 26, 28 and 30 in the several rows of teeth depicted. FIG. 2 is a view taken through teeth 32, 34 and 36 which clearly shows the spaced relation of the teeth. The crest lines of the teeth are curved and the curvatures lie in different radii of curvature as measured from and along axis X--X. This difference of radii for the teeth crest lines results in a curved bounding profile in the plane containing the teeth crests. This allows in different rows of teeth to contact the well casing depending upon the internal diameter of the well casing. Tubular gripping member 10 is rotated by an annular member of the well tool contacting end surface 32 and moving toward point C. This action moves end surface 32 into a generally perpendicular relation toward a well tool mandrel extending though the gripping member and simultaneously brings the toothed segments 14 and 16 into engagement with the wellbore casing interior.
Due to the fact that tubular gripping member 10 rotates to achieve engagement, a different amount of rotation about the pivot axis, indicated at C, is needed for each different internal diameter casing size. Because of this, the lower tooth crest line 24 will contact the interior surface of a smaller diameter casing upon a relatively small rotation of tubular gripping member 10 about rotating point C. However, when the tubular gripping member is positioned within a larger diameter casing, a greater rotation of tubular gripping member 10 will be necessary for the other increasingly larger diameter tooth crest lines 26, 28 and 30 to contact the casing interior of the larger diameter casing. Because of the different diameters of the tooth crest radii as exhibited by lines 24-30 of each succeedingly larger diameter crest will engage the interior of the well casing in relation to the amount of tubular gripping member rotation around point C.
Referring to FIG. 3, the spacing of the plurality of individual insert teeth elements is done in order to provide a sufficient quantity of the teeth elements in each of the rows for effectively and positively gripping the casing when the well tool is set. Positioning of the insert teeth elements in a spaced relation in each of the rows and off-setting the teeth elements from row to row around the periphery of the tubular gripping member allows for maintaining a generally uniform spaced relation between the insert teeth elements and correctly positioning the crest lines of each row of teeth in an uniform spaced relation to each other. The thickness of the insert teeth elements is such that a sufficient portion of each tooth element extends from tubular gripping member 10 to substantially engage the well casing. Because the gripping surfaces of the tubular gripping member 10 must engage the well casing sufficiently to retain the well tool in place against first forces exerted on it during well servicing and pumping processes and the like, there must be sufficient area of each gripping surface engaged in the well casing to prevent any inadvertent sliding movement of the tubular gripping member within the well casing after it is positioned to secure the well tool. The number of teeth in the exposed combined area of the several rows of teeth which is exposed must necessarily be selected to provide a sufficiently available gripping area or contact surface for engaging or digging into the well casing for retaining the tubular gripping member and the associated well tool in place.
By utilizing insert teeth elements constructed of a material which is substantially harder than the typical well casing, this permits the teeth elements to easily dig into or grippingly engage the well casing when tubular gripping member 10 is rotated for setting the well tool. Because of the relatively harder individual teeth elements, they have a tendency to readily grippingly engage the well casing in a positive manner once they are brought into contact with the well casing surface. This is particularly important when the tubular gripping member is utilized on a hydraulically set packer. In this instance, the packer is set by having a substantially large fluid force applied to the setting mechanism of the packer. When this force is applied, it sets the packer and has a tendency to displace the packer downwardly within the casing or wellbore. Because of the novel individual insert teeth elements of this tubular gripping member, they dig in or grippingly engage the well casing upon contact and thereby prevent motion of the well packer within the casing. In the event that a very large fluid force is applied to the packer which is substantially above that required for setting of the hydraulically actuated packer, then some sliding motion of the packer sealing elements and the tubular gripping member may occur within the well casing. In this circumstance, the very hard nature of the individual teeth elements will insure that they are not damaged as the tubular gripping member slides through the casing in the rotated position with the teeth sliding on the interior surface of the casing. Once the teeth have slid in the interior of the casing, they will dig into or grippingly engage the casing when the forces causing the sliding motion decrease or the sliding motion ceases. It is to be noted that when utilizing the above described carbide material for the insert teeth elements, sliding motion in the casing does not appreciably deteriorate the crest portion of the teeth sufficiently to significantly affect performance of the tubular gripping member. It can be seen from the above that a tubular gripping member is provided which will consistently and positively grip the well casing under normal as well as adverse circumstances. The usage of a plurality of insert teeth elements on a face of the tubular gripping member which contacts the well casing provides a structure for presenting a very hard tooth surface on the gripping surface of the tubular gripping member. The positioning of the plurality of teeth elements is such that the tubular gripping member will operate effectively and consistently within a range of casing bore diameters.
One preferred embodiment of the present invention has been described herein in order to provide an understanding of the general principles of the invention. It is to be understood that various changes and refinements to the invention can be affected in the described gripping member for well tools without departing from the scope of the invention and these general principles. All modifications and changes of this nature are deemed to be within the spirit and scope of the invention except as limited by the appended claims or reasonable equivalence thereof. | A unitary tubular cylindrical gripping member for well tools has variable angled gripping surfaces formed thereon by a plurality of insert teeth elements arranged to provide constant positive gripability of the gripping member in well casings. | 4 |
CROSS-REFERENCE TO RELATED PATENTS
This application is a continuation-in-part of U.S. patent application Ser. No. 09/608,712, filed Jun. 30, 2000, now U.S. Pat. No. 6,490,890, issued Dec. 10, 2002, the entire disclosure of which is hereby incorporated by reference, and is referred to as herein as the “parent.”
BACKGROUND OF THE INVENTION
(1) Field of the Invention
The present invention relates generally to knitted textile articles and, more particularly, to a knitted preform for forming a panty, pantyhose or similar article.
(2) Description of the Prior Art
Typically, panty fabric is knit as a tube of fabric with an elastic band for the waist at one end. The end of the tube opposite of the waistband includes some lines formed by the machine during knitting to guide the cut out for the legs. This fabric is cut away and wasted. Then elastic is sewn to make the leg opening. The tube is then closed with a seam in the bottom. Likewise, a footie is knit as a tube, cut and then one end sewn to form the toe. However, reciprocation is normally needed.
Thus, there remains a need for a new and improved knitted preform for making a panty while, at the same time, having the elastic for the legs already in place.
SUMMARY OF THE INVENTION
The present invention is directed to knitted textile articles and a preform forming a panty, pantyhose or similar article. The preform includes a tubular knit body and a pair of opposed longitudinal segments extending the length of the tubular body. The longitudinal segments include complete and partially omitted courses, which produces a unique shape suitable as a preform for subsequently forming other useful textile articles. In the preferred embodiment, the longitudinal segments further include elastic yarn, which aids in forming the shape of the preform. Also, in the preferred embodiment, elastic end bands are formed during knitting to each end of the knitted article. These end bands then become a part of the final textile article.
In one embodiment, disclosed in the parent application, a substantially longitudinal cut is made through the tubular knit body opposite from the longitudinal segment, thereby forming a panty. A waistband may then be attached to the substantially longitudinal cut through the tubular knit body. Also, a pair of hose may be attached to the end bands, thereby forming a pair of pantyhose.
In another embodiment, disclosed in the parent application, a substantially longitudinal cut is made through the longitudinal segment opposite from the tubular knit body, thereby forming a footie. Stitching may then be added to connect the cut ends of the elastic end bands.
Accordingly, one aspect of the present invention is to provide a knitted article. The article includes a tubular knit body; and a pair of opposed longitudinal segments extending the entire length of the tubular body, the longitudinal segments including both complete and partially omitted courses.
Another aspect of the present invention is to provide a knitted article. The article includes a tubular knit body; and a pair of opposed longitudinal segments extending the entire length of the tubular body, the longitudinal segments including partially omitted courses, the longitudinal segments further including elastic yarn.
Still another aspect of the present invention is to provide a knitted article. The article includes: a tubular knit body; a pair of opposed longitudinal segments extending the entire length of the tubular body, the longitudinal segments including partially omitted courses, the longitudinal segments further including elastic yarn; and at least one end band attached to one end of the knitted article.
These and other aspects of the present invention will become apparent to those skilled in the art after a reading of the following description of the preferred embodiment when considered with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a pair of pantyhose made from the apparel preform constructed according to the parent invention;
FIG. 2 is a side perspective view of an apparel preform of the parent invention;
FIG. 3 is a partial perspective view of the parent invention, showing an end band that has been doubled back;
FIG. 4 is a series of perspective views showing how the apparel of the parent invention is used to produce a panty or a pair of pantyhose;
FIG. 5 is a series of perspective views showing how the apparel of the parent invention is used to produce a footie;
FIG. 6 is a schematic diagram showing how the longitudinal section of the tubular knit body is formed by omitting courses;
FIG. 7 is a schematic diagram of a contour knitting pattern;
FIG. 8 is a schematic diagram of the courses used to knit the end bands of the apparel preform of the parent invention; and
FIG. 9 is a perspective view of a pair of pantyhose made from the apparel preform constructed according to the present invention;
FIG. 10 is a side perspective view of an apparel preform of the present invention; and
FIG. 11 is a series of perspective views showing how the apparel of the present invention is used to produce a panty or a pair of pantyhose;
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the following description, like reference characters designate like or corresponding parts throughout the several views. Also in the following description, it is to be understood that such terms as “forward,” “rearward,” “left,” “right,” “upwardly,” “downwardly,” and the like are words of convenience and are not to be construed as limiting terms.
Referring now to the drawings in general and FIG. 1 in particular, it will be understood that the illustrations are for the purpose of describing a preferred embodiment of the invention and are not intended to limit the invention thereto. As best seen in FIG. 1, a panty, pantyhose or similar article, generally designated 10 , is shown constructed according to the parent invention. The textile article 10 includes a knitted preform 12 including a tubular knitted body 14 and a longitudinal segment having partially omitted courses 16 . End bands 20 , 22 form the leg openings and leggings 30 are attached to the leg openings.
The knitted preform 12 of the parent invention is best seen in FIG. 2 . In the preferred embodiment, the knitted preform 12 is a jersey knit. The longitudinal section 16 is formed by partially omitting some of the yarn courses. The longitudinal section 16 thus contains less fabric than the remainder of the tubular knit body 14 , thereby forming the asymmetric knitted preform 12 . In the preferred embodiment, the longitudinal section 16 preferably comprises between about 25 and 33% of the tubular knit body 14 . The actual amount depends on the panty or footie size being formed.
A schematic of the successive dropping of courses that is used to form the longitudinal section(s) 16 in both the parent application and the present invention is shown in FIG. 6 . In the preferred embodiment, the longitudinal section 16 is formed by successively stopping knitting on needles and knitting is performed only on every fourth course as shown in FIG. 7 . In order to better accommodate the shape of the human body, the longitudinal 16 may be knit in a contoured pattern of staggered ends, such as that shown in FIG. 8 . The contoured pattern is formed by stopping knitting on successive courses at different points. The pattern can be then be repeated or altered as desired to yield the proper garment contour or fit.
In the preferred embodiment in both the parent application and the present invention, the knitted preform 12 is knitted from nylon and an elastic yarn, such as Spandex or Dorlastan (manufactured by Bayer Corp., Bushy Park S.C.) and has a ratio of elastic to nylon ends of about 3:1. Referring back to FIG. 7, the elastic end is preferably knit on every fourth needle. Thus, three courses of nylon are knit, followed by a course of elastic yarn, which is knit while being kept under partial tension.
As best seen in FIG. 3 in both the parent application and the present invention, the fabric at each of the end bands 20 , 22 is doubled back and knit into the tubular knit body 14 , thereby forming an elastic leg or foot band. In the present invention, a single end band 20 may be used to form the elastic leg or foot band as will be described in more detail later. The width of the doubled back portion is between ⅛ and ½ inch and preferably about ¼ inch.
A garment, such as a panty or a pair of pantyhose 10 (such as shown in FIG. 1 ), may be made from the knitted preform 12 of the parent invention according to the sequence shown in FIG. 4 in the parent application. A finished knitted preform 12 of the preferred embodiment is shown in FIG. 4 A. FIG. 4B shows a longitudinal cut 24 made in the tubular knit body 14 . The hole created by the longitudinal cut 24 forms the waist of the garment. A waistband 26 , shown in FIG. 4C, is sewn onto the edge formed by the longitudinal cut 24 . As such, the longitudinal cut 24 does not extend the entire length of the tubular body 14 and is positioned to ensure a proper fit of the garment. The end bands 20 , 22 form the leg holes for the garment and the longitudinal section 16 forms the crotch. As shown in FIG. 4D, pantyhose 10 are finished by attaching legs 30 to the knitted preform 12 at end bands 20 , 22 .
FIG. 5 illustrate how a footie is formed from the knitted preform 12 in the parent application. The knitted preform 12 for a footie, shown in FIG. 5A, may be much smaller than the preform for a panty shown in FIG. 4 A. First, a longitudinal cut 32 is made through the longitudinal section 16 of the tubular knit body 14 as seen in FIG. 5 B. The longitudinal cut 32 extends through end bands 20 , 22 , creating two ends on each end band. End bands 20 and 22 are joined at 34 to complete the footie 36 as shown in FIG. 5 C.
In operation in both the parent application and the present invention, the preform for making a panty or a pair of pantyhose is made on a single cylinder fine gauge knitting machine. Starting at one end of the product the yarns start knitting on each of the feeds like a normal make up using the dial bitts and form a double elastic band or using the needles and make a double elastic band. After the band is complete, the feeds start knitting on only a portion of the needles and the yarn of each feed comes out and is trimmed. The amount of needles that knit is determined by the size of the panty and crotch area. This area may be changed during the knitting of the product to form a crotch that is wider in the back than front or any shape to fit the specific item being produced. It may vary to any amount of needles according to whatever amount of coverage you wish in the crotch.
The feeds that are knitting on only a portion of the needles may knit plain or pattern with textured nylon or any type of yarn. The feeds that are knitting on all the needles in the cylinder may have a covered spandex, cotton or any other type of yarn.
After knitting in the parent application, the garment is slit on a line that is created by the machine while the product is being knit. This slit line may be in the center of the area that forms the panty or it may be off center if more fabric is needed for the back or front. After slitting, elastic is sewn around the area to form the elastic for the waistband. This creates a panty without seams with the elastic for the legs already in place.
In operation in the parent application, the preform for making a footie is made on a single cylinder fine gauge knitting machine. Starting at one end of the product the yarns start knitting on each of the four feeds like a normal make-up and then every other needle stops knitting and stays at the low position to hold the yarn it picked up and not to pick up any more yarn. One feed includes covered spandex and the other feeds have textured nylon. In this way, the starting end of the fabric is held by the needles in the low position until the desired amount of fabric is knit. Then the needles that are in the low position start knitting normally for one revolution of the cylinder and this knits the starting end of the fabric back into the regular fabric and forms a double fabric to make an elastic band.
After the band is complete, three of the four feeds start knitting on only a portion of the needles and the yarn of each feed comes out and is trimmed. The amount of needles that knit is determined by the size of the footie that is being produced. It may vary from 300 to 350 or whatever amount of coverage you wish for the footie. The three feeds that knit are knitting only on the needles that are knitting plain knit with textured nylon yarn. The one feed that is knitting on all the needles in the cylinder includes a double covered spandex yarn and may knit a 1×1 tuck or in some styles may knit plain. If the feed that is knitting on all needles is making a 1×1 tuck then it may be using the 1×tuck only on the needles that are not knitting on the other three feeds. Knitting this way helps insure that the stitches will not run when the garment is slit.
After knitting in the parent application, the garment is slit on the center of the side that not much fabric is produced on. It is then seamed on a sewing machine at the ends of the double elastic bands. This forms a footie without a seam in the bottom and does not use a machine with reciprocation.
As best seen in FIG. 9, a panty, pantyhose or similar article, generally designated 10 ′, is shown constructed according to the parent invention. The textile article 10 ′ includes a knitted preform 12 ′ including a tubular knitted body 14 ′ and a pair of opposed longitudinal segments having both complete and partially omitted courses 16 ′. An end band 20 ′ is cut and sewn by a seam 28 to form the leg openings and/or leggings 30 are attached to the leg openings. A second end band 22 ′ may be used to form a waistband.
The knitted preform 12 ′ of the present invention is best seen in FIG. 10 . In the preferred embodiment, the knitted preform 12 ′ may be a jersey knit. The longitudinal sections 16 ′ are formed by partially omitted some of the yarn courses. The longitudinal sections 16 ′ thus contain less fabric than the remainder of the tubular knit body 14 ′, thereby forming the asymmetric knitted preform 12 ′. In the preferred embodiment, the longitudinal sections 16 ′ preferably comprise between about 25 and 33% of the tubular knit body 14 ′. The actual amount depends on the panty size being formed.
A schematic of the successive dropping of courses that is used to form the longitudinal sections 16 ′ was shown in FIG. 6 as described above.
A garment, such as a panty or a pair of pantyhose 10 ′ (such as shown in FIG. 9 ), may be made from the knitted preform 12 ′ of the present invention according to the sequence shown in FIG. 11. A front view of a finished knitted preform 12 ′ of the preferred embodiment is shown in FIG. 11 A. FIG. 11B shows a back view of a finished knitted preform 12 ′. As can be seen, the longitudinal sections 16 ′ are preferably varied along the length of the knitted preform 12 ′ for fit. As shown in FIG. 11C, end band 20 ′ is cut and sewn along seam 28 to form the leg openings. A second end band 22 ′ may be used to form a waist band. As shown in FIG. 11D, pantyhose 10 ′ are finished by attaching legs 30 to the knitted preform 12 ′ at cut and sewn end band 20 ′.
Certain modifications and improvements will occur to those skilled in the art upon a reading of the foregoing description. It should be understood that all such modifications and improvements have been deleted herein for the sake of conciseness and readability but are properly within the scope of the following claims. | A knitted textile articles and a preform forming a panty, pantyhose or similar article. The preform includes a tubular knit body and a pair of opposed longitudinal segments extending the length of the tubular body. The longitudinal segments include both complete and partially omitted courses, which produces a unique shape suitable as a preform for subsequently forming other useful textile articles. In the preferred embodiment, the longitudinal segments further include elastic yarn, which aids in forming the shape of the preform. Also, in the preferred embodiment, elastic end bands are formed during knitting to each end of the knitted article. These end bands then become a part of the final textile article. | 3 |
BACKGROUND
[0001] The invention concerns a switch assembly for switching electrical currents in a motor vehicle with a switch component, an actuator and an icon display located on the actuator.
[0002] Switch assemblies of this type are used in extremely large numbers, for example, in the instrument panel of motor vehicles.
[0003] Because of the low manufacturing costs, the manufacturers of these switch assemblies are interested in producing them in very large quantities in the same design. However, among the buyers of these switch assemblies, for example, the manufacturers of motor vehicles, there are trends in the opposite direction: in spite of large numbers, motor vehicles are being tailored more and more to the customers wishes.
[0004] In order to address this dilemma of large numbers of switch assemblies of the same style on the one hand and the desire of the buyers for individual designs for the switch assemblies, providing a switch with an interchangeable actuator is known. On page 308 of the March/August 1996 catalog from RS Components GmbH, Hessenring 13b, 64546 Mörfelden-Waldorf, a power switch is offered (order number 664-165) for which various pushbutton switches or lenses are offered. The disadvantage of this method of construction is that the actuator is connected detachably to the switch, and thus the switch becomes non-functional if the actuator is detached from the switch.
[0005] The object of the invention is to provide a switch assembly for switching electrical currents, which on the one hand can be produced in very large quantities and on the other hand allows an individual customer-specific design with simultaneous high operational safety for the switch.
SUMMARY
[0006] The object is met by the invention by means of a switch assembly for switching electrical currents with a switch element, with an actuator and with a icon display located on the actuator, where the icon display is made as a separate component attached to the actuator, so that, without separating the switch assembly and the actuator from one another, the design of the switch assembly can be changed by replacing the icon display. Consequently, it is possible on the one hand to manufacture switches and actuators in the maximum quantity and to assemble switches and actuators during the production process into a functional unit. On the other hand, it is possible, by changing the icon display, to adapt the appearance of the switch according to the invention individually to the customer's wishes and to achieve greater acceptance with the customer. By changing the icon display, the technically identical switch can be sold to different customers with a different design.
[0007] The object is also achieved by means of a switch assembly for switching electrical currents in a motor vehicle, with a switch element, an actuator and an icon display which is designed as a separate component attached to the switch assembly, so that the design and the function of the switch assembly is determined by applying the icon display to the switch assembly. Modifications to the design can be made simply and economically without affecting the manufacture of the switch assembly.
[0008] To supplement the invention, provision is made for attaching the icon display to the actuator or to the switch assembly by a snap connector, so that the attachment of the icon display and the actuator can be realized or released without special tools and in a very simple fashion.
[0009] A variation of the invention provides for making the symbol releasably attached to the actuator or the switch assembly, so that the appearance of the switch assembly can be changed during the service life of the switch by replacing the icon display. This makes it possible, for example, to achieve a like-new visual impression and/or a more modern appearance in second-hand vehicles by replacing the icon display.
[0010] In another embodiment of the invention, provision is made for the icon display to have one or more locking means and for the one or more locking means to activate or deactivate one or more functions of the switch. The locking means can lock out the switching motion of the switch assembly, so that unintentional actuation of the switch assembly is prevented. Alternatively, the locking means can be designed in such a way that when the icon display is applied, the ultimate function of the switch is established to match the icon. In this way, a switch assembly having several functions can be produced in even larger quantities, and the function of the switch is not determined until the symbol display is applied.
[0011] As a supplement to the invention it is intended that the switch is a rocker switch and/or that the switch element is designed to be touch operated, so that the switch according to the invention can be used for different purposes.
[0012] In a further embodiment of the invention, the icon display and/or the actuator can be illuminated, so that the switch according to the invention can be identified and operated easily even in the dark.
[0013] In another embodiment of the invention, the icon display extends at least over almost the entire length of the actuator panel so that adequate space is available for depicting one or more icons which indicate the function of the switch assembly. In addition, as the result of the elongated design of the icon display, the switch assembly according to the invention has an elegant and streamlined appearance.
[0014] Additional advantages and advantageous embodiments of the invention can be seen in the drawing and its description as well as the appended patent claims.
BRIEF DESCRIPTION OF THE DRAWING
[0015] [0015]FIG. 1 is a perspective view of a switch according to the invention;
[0016] [0016]FIG. 2 is a perspective view of several switches according to the invention, some with the icon display removed;
[0017] [0017]FIG. 3 is a perspective view of another embodiment of several switch assemblies according to the invention; and
[0018] [0018]FIG. 4 is a perspective view of a switch according to the invention with locking means.
DETAILED DESCRIPTION
[0019] [0019]FIG. 1 shows a first embodiment of a switch assembly 1 according to the invention implemented as a switch. The switch assembly 1 has an actuator 3 , which can be moved to different switch positions. An icon display 5 is applied on the top side of the actuator 3 extending over the entire length of the actuator panel 3 . The icon display 5 contains a symbol 7 for function “a” of a motor vehicle, for example, and a symbol 9 for function “b” of a motor vehicle, for example. In the center switch position of the switch assembly 1 shown in FIG. 1, the functions “a” and/or “b” can be switched off depending on the implementation of the switch assembly. If the operator of the motor vehicle presses the actuator 3 in the area of the symbol 7 , function “a” headlamps, for example, is switched on; if he presses the actuator 3 in the area of the symbol 9 , function “b” is switched on. Icons of this kind were applied previously by means of pad printing, embossed sheet, lasers or similar means directly onto the actuator 3 . With this method there is the accompanying necessity of determining the function of the switch assembly according to the invention at the time of production. In addition, the exterior form of the switch assembly apparent to the operator of the motor vehicle is determined once and for all when the icon is imprinted.
[0020] [0020]FIG. 2 shows perspective drawings of several switch elements according to the invention. The switch assemblies 11 and 13 have no icon displays on the actuators 3 . In an exploded view, the icon displays 5 are shown above the corresponding switches 11 and 13 . From this drawing it is clear that the function of the switches 11 and 13 according to the invention is determined only when the icon displays 5 are applied. In this respect, the switch element according to the invention can be produced continuously in very large quantities, and the function of the switch assembly is not determined until an order is received, when the corresponding icon display 5 is applied to the switch assembly 11 or 13 . The connection of icon display 5 and actuator 3 can be achieved by a releasable or non-releasable attachment.
[0021] Naturally, it is also conceivable that the buyer of the switch component according to the invention designs the icon field 5 himself and also produces it himself. There is a standardization of switch assemblies in a motor vehicle in as much as the same switch component can be used for different functions, and it only has to adapted by using another icon display.
[0022] [0022]FIG. 3 is a perspective drawing of a row of possible switch assemblies 15 according to the invention positioned next to one another. In the case of these switch assemblies, the icon displays 5 have printable areas 16 of different sizes. This further increases the design latitude of the switch assemblies 1 according to the invention.
[0023] In a first design shape in accordance with FIG. 3, the printable area 16 extends over almost the entire length of the icon display 5 . In one of the next switch assemblies 15 , the printable area 16 is positioned in the middle of the icon display 5 . On both sides of the printable area 16 , textured gripping surfaces can be located on the icon display 5 or the actuator 3 , which make operation easier. The other switch assemblies 15 shown in FIG. 3 show different versions of the icon displays 5 and printable areas 16 . One of the icon displays extends from one end of the display to beyond the center, while in the case of the other switch assemblies, the printable areas 16 are located at the end of the icon display.
[0024] The invention is not restricted to rocker switches, but can also be used for pushbuttons, locking switches and pushbutton switches. The icon displays 5 can also be designed in such a way that they can be installed rotated by 180°.
[0025] [0025]FIG. 4 shows an additional embodiment of a switch assembly 1 according to the invention. An icon bar 5 with a symbol 7 and a locking element 17 are located on the actuator 3 . The locking element 17 is can be moved in the direction of the longitudinal axis of the actuator 3 between two positions, not shown in FIG. 4. In a first position of the locking element 17 , the actuator 3 can be moved back and forth between its switch positions, which are also not shown. In a second position of the locking element 17 , it locks the actuator 3 , so that the latter remains in its switched position. This effectively inhibits any unintentional operation of the actuator 3 .
[0026] All features presented in the description, the drawing and the patent claims can be essential to the invention both individually and in any combination with one another. | A switch assembly for switching electrical currents in which a separate icon display is provided. The icon display can be attached to either the actuator of the switch assembly or the switch assembly so that different designs for one and the same switch assembly are possible without any modifications to the switch assembly. | 1 |
DESCRIPTION
Phenoxyacetic acid derivatives
SUMMARY
This invention is related to phenoxyacetic acid derivatives.
More particularly, this invention is related to:
1) phenoxyacetic acid derivatives of the formula (I): ##STR2## wherein all the symbols are the same meaning as hereafter defined, and non-toxic salts thereof and non-toxic acid addition salts thereof,
2) processes for the preparation thereof, and
3) pharmaceutical agents containing them as active ingredient.
BACKGROUND OF THE INVENTION
Prostaglandin I 2 (PGI 2 )is a physiologically active natural substance having the following structural formula, which is biosynthesized from Prostaglandin H 2 (PGH 2 ) in the metabolic process the called arachidonate cascade. ##STR3## (see Nature, 263, 663(1976), Prostaglandins, 12, 685(1976), ibid, 12, 915(1976), ibid, 13, 375(1977) and Chemical and Engineering News, Dec. 20, 17(1976)).
PGI 2 has been confirmed to possess not only a very strong inhibitory activity on blood platelet aggregation but a dissociative activity on blood platelet aggregation, an inhibitory activity on blood platelet adhesion, a vasodilating activity, an inhibitory activity on gastric acid secretion etc. Therefore, it has been considered that PGI 2 is useful for the prevention and/or the treatment for thrombosis, arteriosclerosis, ischemic heart diseases, gastric ulcer, hypertension etc. But its application as a pharmaceutical is limited because of its chemical instability and the difficulty in separating the activities according to purpose. Accordingly, various PGI 2 derivatives have been synthesized and much research has been carried out for the maintenance and the separation of the activities. However, no satisfactory results have been obtained.
Recently, to solve two problems described above, research for PGI 2 receptor agonists which have a new skeleton and which may be useful for the treatment of or for the prevention of the above diseases, in view of PGI 2 receptor level, has been carried out.
RELATED ARTS
It has been reported in the literature that the following compounds not having the PGI 2 skeleton are PGI 2 receptor agonists which bind to a PGI 2 receptor and inhibit blood platelet aggregation: ##STR4## (see Brit. J. Pharmacol., 76, 423(1982), ibid, 84, 595(1985), and the Japanese Patent Kohyo No. 55-501098), ##STR5## (see Brit. J. Pharmacol., 76, 423(1982), ibid, 84, 595(1985), and the Japanese Patent Kohyo No. 57-501127), ##STR6## (see Brit. J. Pharmacol., 102, 251-266(1991) and the West German Patent Publication No. 3,504,677), and ##STR7## (see U.S. Pat. No. 5,011,851).
PURPOSE OF THE INVENTION
Energetic investigation has been carried out to discover new PGI 2 receptor agonists having a skeleton with a chemical structure different from the compounds mentioned above. The present inventors have found that phenoxyacetic acid derivatives can bind to PGI 2 receptor and have an inhibitory activity on blood platelet aggregation.
The phenoxyacetic acid derivatives of formula (I), of the instant invention are novel and it is not possible to predict from the above compounds known as PGI 2 receptor agonists, that the compounds of the instant invention are PGI 2 receptor agonists.
DETAILED DISCLOSURE OF THE INVENTION
The present invention is related to:
1) Phenoxyacetic acid derivatives of the formula (I): ##STR8## wherein A is i) --CR 1 ═N˜OR 2 ,
ii) --CHR 1 --NH--OR 2 ,
iii) --COE,
iv) --SO 2 E,
v) --CH 2 --NR 3 --Y,
vi) --Z--NR 3 --CONR 4 R 5 ,
vii) --CH 2 --OR 6 ,
viii) --CO 2 R 6 ,
ix) --CH 2 --O˜N═CR 7 R 8 ,
x) --CH 2 --O--NHCHR 7 R 8 , ##STR9##
T is
i) single bond,
ii) C1-6 alkylene,
iii) C2-6 alkenylene or
iv) --O--(CH 2 ) s --;
D is
i) --CO 2 R 10 or
ii) --CONR 11 R 12 ;
E is
i) --NR 4 R 5 ,
ii) --NR 3 OR 6 ,
iii) --NR 3 --NR 4 R 5 or
iv) --NR 3 --N═CR 4 R 5 ;
Y is
i) --COR 6 ,
ii) --CO--L--NR 4 R 5 ,
iii) --CS--NHR 4 or
iv) --SO 2 R 6 ;
Z is
i) --CH═N-- or
ii) --CH 2 --NR 3 --;
L is single bond or C1-4 alkylene;
R 1 is hydrogen, C1-6 alkyl or phenyl;
R 2 is i) C1-8 alkyl substituted by one or two of phenyl, 4-7 membered monocyclic hetero ring containing one nitrogen or C4-7 cycloalkyl,
ii) C10-15 hydrocarbon condensed tricyclic ring or
iii) C1-15 alkyl;
R 3 is hydrogen, C1-6 alkyl or phenyl;
R 4 and R 5 each, independently, is
i) hydrogen,
ii) phenyl,
iii) 4-7 membered monocyclic hetero ring containing one nitrogen or
iv) C1-4 alkyl substituted by one or two of phenyl or 4-7 membered monocyclic hetero ring containing one nitrogen;
R 6 is
i) phenyl,
ii) 4-7 membered monocyclic hetero ring containing one nitrogen or
iii) C1-4 alkyl substituted by one to three of phenyl or 4-7 membered monocyclic hetero ring containing one nitrogen;
R 7 is
i) hydrogen,
ii) C1-8 alkyl,
iii) phenyl or C4-7 cycloalkyl,
iv) 4-7 membered monocyclic hetero ring containing one nitrogen or
v) C1-4 alkyl substituted by one or two of phenyl, C4-7 cycloalkyl or 4-7 membered monocyclic hetero ring containing one nitrogen;
R 8 is
i) C1-8 alkyl,
ii) phenyl or C4-7 cycloalkyl
iii) 4-7 membered monocyclic hetero ring containing one nitrogen or
iv) C1-4 alkyl substituted by one or two of phenyl, C4-7 cycloalkyl or 4-7 membered monocyclic hetero ring containing one nitrogen;
R 9 is
i) hydrogen,
ii) phenyl,
iii) C1-4 alkyl or
iv) C1-4 alkyl substituted by one or two of phenyl or 4-7 membered monocyclic hetero ring containing one nitrogen;
R 10 is hydrogen or C1-12 alkyl;
R 11 and R 12 each, independently, is hydrogen or C1-4 alkyl or
R 11 and R 12 , taken together with nitrogen bond to R 11 and R 12 is the residue of an amino acid;
R 13 is hydrogen, C1-4 alkyl, C1-4 alkoxy or nitro;
m is 1-3,
n is 1-2,
s is 2-4;
and the rings of R 1 , R 2 , R 3 , R 4 , R 5 , R 6 , R 7 , R 8 and R 9 also may be substitut ed by one to three of C1-C4 alkyl, C1-C4 alkoxy, halogen, nitro or trihalomethyl;
with the proviso that,
(1) when A is --SO 2 E wherein E is the same meaning hereinbefore defined, T is not single bond and C1 alkylene (methylene),
(2) when A is ##STR10## where in R 9 is the same meaning hereinbefore defined, T is not C2-6 alkenylene; and non-toxic salts thereof and non-toxic acid addition salts thereof.
2) Process for the preparation of them and
3) Pharmaceutical agent containing them as active ingredient.
Unless otherwise specified, all isomers are included in the invention. For example, alkyl, alkoxy, alkylene and alkenylene includes straight and branched ones. Double bond in alkenylene and oxime include E, Z and the EZ mixture. Isomers generated by asymmetric carbon(s) e.g. branched alkyl are included in the instant invention.
The compounds of formula (I) of the instant invention, wherein R 10 is hydrogen, may be converted into the corresponding salts by methods known per se. Non-toxic and water-soluble salts are preferable. Suitable salts, for example, am salts of alkaline metals (potassium, sodium, etc.), salts of alkaline earth metals (calcium, magnesium, etc.), ammonium salts, salts of pharmaceutically-acceptable organic amines (tetramethylammonium, triethylamine, methylamine, dimethylamine, cyclopentylamine, benzylamine, phenethylamine, piperidine, monoethanolamine, diethanolamine, tris(hydroxymethyl)amine, lysine, arginine, N-methyl-D-glucamine) etc..
The compounds of formula (I) may be converted into the corresponding acid additional salts by methods known per se. Non-toxic and water-soluble salts are preferable. Suitable acid addition salts, for example, are salts of inorganic acids, e.g., hydrochloride, hydrobromide, sulphate, phosphate, nitrate etc., or salts of organic acids, e.g., acetate, lactate, tartarate, oxalate, fumarate, maleate, citrate, benzoate, methanesulphonate, ethanesulphonate, benzenesulphonate, toluenesulphonate, isethioate, glucuronate, gluconate etc.
The compounds of formula (I), salts thereof or acid additional salts thereof may be converted into hydrates thereof by methods known per se.
In formula (I), C1-4 alkylene represented by L means methylene, ethylene, trimethylene, tetramethylene and isomeric groups thereof. C1-6 alkylene represented by T means methylene, ethylene, trimethylene, tetrametylene, pentamethylene, hexamethylene and isomeric groups thereof. C2-6 alkenylene represented by T means ethylene, trimethylene, tetramethylene, pentamethylene, hexamethylene and isomeric groups thereof having one or two double bond.
In formula (I), C1-4 alkyl represented by R 4 , R 5 , R 6 , R 7 , R 8 , R 9 , R 11 , R 12 and R 13 means methyl, ethyl, propyl, butyl and isomeric groups thereof. C1-6 alkyl represented by R 1 and R 3 means methyl, ethyl, propyl, butyl, pentyl, hexyl and isomeric groups thereof. C1-8 alkyl represented by R 2 , R 7 and R 8 means methyl, ethyl, propyl, butyl, pentyl, hexyl, heptyl, octyl and isomeric groups thereof. C1-15 alkyl represented by R 2 means methyl, ethyl, propyl, butyl, pentyl, hexyl, heptyl, octyl, nonyl, decyl, undecyl, dodecyl, tridecyl, tetradecyl, pentadecyl and isomeric groups thereof. C1-12 alkyl represented by R 10 means methyl, ethyl, propyl, butyl, pentyl, hexyl, heptyl, octyl, nonyl, decyl, undecyl, dodecyl and isomeric groups thereof.
In formula (I), C1-4 alkoxy represented by R 13 means methoxy, ethoxy, propoxy, butoxy and isomeric groups thereof.
In formula (I), C4-7 cycloalkyl represented by R 2 , R 7 and R 8 means, for example, cyclopentyl, cyclohexyl and cycloheptyl.
In formula (I), 4-7 membered monocyclic hetero ring represented by R 2 , R 4 , R 5 , R 6 , R 7 , R 8 and R 9 means, for example, pyrrole, pyridine, azepine ring and partially or fully saturated ring thereof (e.g., pyrrolidine, piperidine ring, etc.).
In the formula (I), C10-15 hydrocarbon condensed tricyclic ring means, for example, indacene, fluorene, anthracene, dibenzocycloheptene rings and partially or fully saturated ring thereof.
In formula (I), C1-C4 alkyl as substituents of the rings in R 1 , R 2 , R 3 , R 4 , R 5 , R 6 , R 7 , R 8 and R 9 mean methyl, ethyl, propyl, butyl and isomers thereof. C1-C4 alkoxy means methoxy, ethoxy, propoxy, butoxy and isomers thereof. Halogen and halogen in trihalomethyl means fluorine, chlorine, bromine and iodine atoms.
Examples of representative compounds of formula (I), of the instant invention are:
(1) 3-[2-[2-Phenyl-2-(3-pyridyl)ethyl]oxyiminoethyl]phenoxyacetic acid,
(2) 3-[2-(2-Cyclohexyl-2-phenylethyl)oxyiminoethyl]phenoxyacetic acid,
(3) 3-[2-[2-(Fluorene-9-yl)ethyl]oxyiminoethyl]phenoxyacetic acid,
(4) 3-[2-(2-Phenyldecyl)oxyiminoethyl]phenoxyacetic acid,
(5) 4-(2-Benzoylaminoethyl)phenoxyacetic acid,
(6) 4-[2-(N,N-Diphenylaminocarbonylamino)ethyl]phenoxyacetic acid,
(7) 4-[2-(N,N-Diphenylaminomethylcarbonylamino)ethyl]phenoxyacetic acid,
(8) 4-(2-Phenylaminothiocarbonylaminoethyl)phenoxyacetic acid,
(9) 4-(2-Phenylsulfonylaminoethyl)phenoxyacetic acid,
(10) 4-[2-(N,N-Diphenylaminocarbonylaminoimino)ethyl]phenoxyacetic acid,
(11 ) 3-[3-(2-Diphenylmethylimidazol-5-yl)propyl]phenoxyacetic acid,
(12) 3-[3-(3,4,5-Triphenylpyrazol-1 -yl)propyl]phenoxyacetic acid,
(13) 3-[3-(Oxazol-2-yl)propyl]phenoxyacetic acid,
(14) 3-[3-(5-Ethyloxazol-4-yl)propyl]phenoxyacetic acid,
(15) 3-[3-[5-Di(3-pyridly)methylisoxazol-3-yl]propyl]phenoxyacetic acid,
(16) 3-[3-(4,5-Diphenylimidazolyl)propyl]phenoxyacetic acid,
(17) 3-[3-(5-Diphenylmethylisoxazol-3-yl)propyl]phenoxyacetamide,
(18) Amide of 3-[3-(5-Diphenylmethylisoxazol-3-yl)propyl]phenoxyacetic acid with glycine,
(19) Octyl 3-[3-(5-diphenyimethylisoxazol-3-yl)propyl]phenoxyacetate,
(20) 3-[3-[4-Di(3-pyridyl)methylpyrazol-1-yl]propyl]phenoxyacetic acid,
(21) 2-Methyl-3-[3-[4-[1 -phenyl-1-(3-pyridyl)methyl]pyrazol-1-yl]prop yl]phenoxyacetic acid,
(22) 3-[3-Di(3-pyridyl)methyloxyiminopropyl]phenoxyacetic acid,
(23) 3-[3-[Di(3-pyridyl)methylideneaminooxy]propyl]phenoxyacetic acid,
(24) 3-[3-[1-cyclohexyl-1-Phenylmethylideneaminooxy]propyl]phenoxyacetic acid,
(25) 2-Methyl-3-[3-[1-phenyl-1 -(3-pyridyl)methylideneaminooxy]propyl] phenoxyacetic acid,
(26) 3-(3-Diphenylmethyloxyaminosulfonylpropyl)phenoxyacetic acid,
(27) 3-[3-[(N,N-Diphenylamino)aminosulfonyl]propyl]phenoxyacetic acid,
(28) 3-[3-[(1,1-Diphenylmethylideneamino)aminosulfonyl)propyl]phenoxy acetic acid,
(29) 4-[2-[(N,N-Diphenylaminocarbonylamino)amino]ethyl]phenoxyacetic acid,
(30) 3-[3-[5-[1-Phenyl-1-(3-pyridyl)methyl]isoxazol-3-yl]propyl]phenoxyacetic acid,
(31) 3-[4-Methyl-4-(1-phenyl-1-(3-pyridyl)methyloxyimino)butyl]phenoxyacetic acid,
(32) 3-[2-[4-[1-Phenyl-1-(3-pyridyl)methyl]pyrazol-1-yl]ethyl]phenoxyacetic acid,
(33) 3-[3-[1-Phenyl-1-(3-pyridyl)methylaminooxy]propyl]phenoxyacetic acid,
non-toxic salts thereof, non-toxic acid addition salts thereof and those described in the examples below.
PROCESS FOR THE PREPARATION
The compounds of the instant invention of the formula (I), may be prepared:
(i) by reacting a compound of formula (III): ##STR11## wherein R 10a means methyl or ethyl and the other symbols have the same meaning as hereinbefore defined,
with a compound of formula (a):
R.sup.2 ONH.sub.2 (a)
wherein R 2 has the same meaning as hereinbefore defined, p (ii) by subjecting a compound obtained by reaction (i) of formula (Ia-1): ##STR12## wherein all the symbols have the same meaning as hereinbefore defined, to reduction,
(iii) by amidation of a compound of formula (IV): ##STR13## wherein all the symbols have the same meaning as hereinbefore defined, with a compound of formula (b):
H E (b)
wherein E has the same meaning as hereinbefore defined,
(iv) by subjecting a compound of formula (VI): ##STR14## wherein T a is single bond, C1-4 alkylene, C2-4 alkenylene or --O--(CH 2 ) t -- wherein t is 0-2, and the other symbols have the same meaning as hereinbefore defined, to Jone's oxidation,
(v) by subjecting a compound obtained by reaction (iv) of formula (Ib-1): ##STR15## wherein all the symbols have the same meaning as hereinbefore defined, to hydrogenation (including a series of reactions subjecting a compound of formula (Ib-1) to methylesterification, and to hydrogenation, followed by hydrolysis of the ester bond, for the convenience of purification),
(vi) by amidation or thioamidation of a compound of formula (VIII): ##STR16## wherein all the symbols have the same meaning as hereinbefore defined, with a compound of formula (c):
R.sup.6 CO.sub.2 H (c)
wherein R 6 have the same meaning as hereinbefore defined, or with a compound of formula (d):
R.sup.4 R.sup.5 N--L--CO.sub.2 H (d)
wherein all the symbols have the same meaning as hereinbefore defined, or with a compound of formula (e):
R.sup.4 --N═C═S (e)
wherein R 4 has the same meaning as hereinbefore defined, or with a compound of formula (f):
R.sup.6 SO.sub.2 Cl (f)
wherein R 6 is the same meaning as hereinbefore defined,
(vii) by reacting a compound of formula (VII): ##STR17## wherein all the symbols have the same meaning as hereinbefore defined, with a compound of formula (g):
H.sub.2 N--NR.sup.3 --CONR.sup.4 R.sup.5 (g)
wherein all the symbols have the same meaning as hereinbefore defined,
(viii) by subjecting a compound obtained by reaction (vii) of formula (Ia-5): ##STR18## wherein all the symbols have the same meaning as hereinbefore defined, to reduction,
(ix) by reacting a compound obtained by reaction (viii) of formula (Ia-6): ##STR19## wherein all the symbols have the same meaning as hereinbefore defined, with a compound of formula (h):
R.sup.3a I (h)
wherein R 3a is C1-6 alkyl or phenyl,
(x) by reacting a compound of formula (II): ##STR20## wherein all the symbols have the same meaning as hereinbefore defined, with a compound of formula (i): ##STR21## wherein R 6 has the same meaning as hereinbefore defined, or with a compound of formula (s):
R.sup.6 X (s)
wherein X has halogen and R 6 is the same meaning as hereinbefore defined,
(xi) by esterification of a compound of formula (IV): ##STR22## wherein all the symbols have the same meaning as hereinbefore defined, with a compound of formula (j):
R.sup.6 OH (j)
wherein R 6 has the same meaning as hereinbefore defined,
(xii) by reacting a compound of formula (IX): ##STR23## wherein all the symbols have the same meaning as hereinbefore defined, with a compound of formula (k):
G H (k)
wherein G is ##STR24## wherein all the symbols have the same meaning as hereinbefore defined, or with a compound of formula (q):
HO˜N═CR.sup.7 R.sup.8 (q)
wherein all the symbols have the same meaning a hereinbefore defined, or with a compound of formula (r):
HO--NH--CHR.sup.7 R.sup.8 (r)
wherein all the symbols have the same meaning as hereinbefore defined,
(xiii) by reacting a compound of formula (x): ##STR25## wherein all the symbols have the same meaning as hereinbefore defined, with a compound of formula (I): ##STR26## wherein R 9 has the same meaning as hereinbefore defined,
(xiv) by reacting a compound of formula (XII): ##STR27## wherein R 9a is phenyl, C1-4 alkyl or C1-4 alkyl substituted by one or two of phenyl or 4-7 membered monocyclic hetero ring containing one nitrogen and the other symbols have the same meaning as hereinbefore defined, or a compound of formula (XIV): ##STR28## wherein all the symbols have the same meaning as hereinbefore defined, or a compound of formula (XVII): ##STR29## wherein all the symbols have the same meaning as hereinbefore defined, or a compound of formula (XXIII): ##STR30## wherein all the symbols have the same meaning as hereinbefore defined, or a compound of formula (XXIX): ##STR31## wherein all the symbols have the same meaning as hereinbefore defined, with a compound of formula (m):
BrCH.sub.2 CO.sub.2 R.sup.10a (m)
wherein R 10a has the same meaning as hereinbefore defined,
(xv) by reacting of a compound of formula (XV): ##STR32## wherein all the symbols have the same meaning as hereinbefore defined, with a compound of formula (n):
R.sup.9 COCl (n)
wherein R 9 has the same meaning as hereinbefore defined,
(xvi) by cyclization of a compound of formula (XVIII): ##STR33## wherein all the symbols have the same meaning as hereinbefore defined,
(xvii) by cyclization of a compound of formula (XX): ##STR34## wherein all the symbols have the same meaning as hereinbefore defined,
(xviii) by hydrolysis of a compound obtained by hereinbefore reaction (i), (ii), (iii), (vi), (vii), (viii), (ix), (x), (xi), (xii), (xiii), (xiv), (xv), (xvi) or (xvii) of formula (Ia): ##STR35##
wherein A a is
i) --CR 1 ═N˜OR 2 ,
ii) --CHR 1 --NH--OR 2 ,
iii) --COE,
iv) --CH 2 NR 3 --Y,
v) --CH═N--NR 3 --CONR 4 R 5 ,
vi) --CH 2 --NH--NR 3 --CONR 4 R 5 ,
vii) --CH 2 --NR 3a --NR 3 --CONR 4 R 5 ,
viii) --CH 2 OR 6 ,
ix) --CO 2 R 6 ,
x) --CH 2 G,
xi) --CH 2 --O˜N═CR 7 R 8 ,
xii) --CH 2 --O--NHCHR 7 R 8 , ##STR36## and the other symbols have the same meaning as hereinbefore defined,
(xix) by esterification of a compound obtained by hereinbefore reaction (iv), (v) or (xviii) of formula (Ib): ##STR37## wherein all the symbols have the same meaning as hereinbefore defined, with a compound of formula (o):
R.sup.10b OH (o)
wherein R 10b is C1-12 alkyl, or
(xx) by amidation of a compound obtained hereinbefore by reaction (iv), (v) or (xviii) of formula (Ib): ##STR38## wherein all the symbols have the same meaning as hereinbefore defined, with a compound of formula (p):
R.sup.11 R.sup.12 NH (p)
wherein all the symbols have the same meaning as hereinbefore defined.
The reaction (i) is known, for example, it may be carried out in an inert organic solvent (tetrahydrofuran (THF), methanol, ethanol, dimethoxyethane, dioxane, mixtures thereof etc.) at 0°-70° C.
The reactions (ii) and (viii) are known, for example, they may be carried out in a water miscible organic solvent (THF, dioxane, methanol, ethanol, dimethoxyethane mixtures thereof etc.), in the presence of an acid (hydrochloric acid, acetic acid, trifluoroacetic acid etc.) using a reducing agent (sodium cyanoborohydride etc.) at 0°-70° C.
The reactions (iii) and (vi) are known, for example, they may be carried out in an inert organic solvent (methylene chloride etc.), in the presence of an appropriate condensing agent (2-chloro-N-methylpyridinum iodide etc.) and a proper base (triethylamine, N,N-dimethylaminopyridine, mixtures thereof etc.) at 0°-40° C.
The reaction (iv) is known, for example, it may be carried out in acetone using a Jone's agent at -10°-40° C.
The reaction (v) is known, for example, it may be carried out in an inert organic solvent (THF, diethylether, dioxane, ethyl acetate, methanol, ethanol, methylene chloride etc.) using a catalyst (palladium on carbon, palladium, hydoxy palladium, palladium acetic acid, palladium black, platinum black etc.) at normal or elevated pressures of hydrogen gas, at 0°-80° C.
The reaction may be carried out, for the convenience of purification, by exposing a compound of formula (Ib-1) to methylestification and to hydrogenation, following hydrolysis of an ester bond. The methylestification is known, for example, it may be carried out in an inert organic solvent (diethylether, ethyl acetate etc.) using diazomethane at 0°-10° C. The hydolysis of an ester bond may be carried out by the same procedure as hereafter defined for reaction (xviii).
The reaction (vii) is known, for example, it may be carried out in an inert organic solvent (methanol, ethanol etc.) under an atmosphere of inert gas at 0°-40° C.
The reaction (ix)is known, for example, it may be carried out in an inert organic solvent (N,N-dimethylformamide (DMF), etc.) in the presence or absence of an appropriate base (sodium hydride etc.).
The reaction (x) is known, for example, it may be carried out in an inert organic solvent (chloroform, cyclohexane, mixtures thereof etc.), in the presence of a Lewis acid (trifluoroborane etherate etc.), or in an inert organic solvent (DMF etc.), in the presence of an amine (N,N-dimethylaminopyridine, triethylamine, pyridine etc.) at 0° C.--a reflux temperature.
The reaction (xi) is known, for example, it may be carried out in an inert organic solvent (methylene chloride etc.) in the presence of an appropriate condensing agent (2-chloro-N-methylpyridinum iodide etc.) and a proper base (triethylamine, N,N-dimethylaminopyridine, mixtures thereof etc.) at 0°-0° C.
The reaction (xii) is known, for example, it may be carried out in inert organic solvent (DMF, THF, etc.) in the presence of an appropriate base (sodium hydride, potassium t-butoxide, n- butyllithium, etc.).
The reaction (xiii) is known, for example it may be carried out in an inert organic solvent (chloroform, etc.) at 0° C.--a reflux temperature.
The reaction (xiv) is known for example, it may be carried out in an inert organic solvent (DMF, acetone, etc.), in the presence of an appropriate base (potassium carbonate etc.) at 0°-50° C.
The reaction (xv) is known it may be carried out at 80°-135° C. without an organic solvent.
The reactions (xvi) and (xvii) are known, for example, they may be carried out in an inert organic solvent (truene etc.) at 0° C.--a reflux temperature.
The reaction (xviii) is known, for example, it may be carried out in an inert organic solvent (methanol, ethanol, dioxane, THF, dimethoxyethane, mixtures thereof etc.) using an aqueous alkali solution (potassium hydroxide, sodium hydroxide, potassium carbonate, sodium carbonate etc.) at 0°-50° C.
The reactions (xix) and (xx) are known, for example, they may be carried out by reacting a compound of the formula (Ib) in an inert organic solvent (methylene chloride etc.) with an acyl halide such as oxalyl chloride, thionyl chloride and then by reacting a compound thus obtained with an alcohol of formula (o) or an amine of formula (p), respecitvely in an inert organic solvent (methylene chloride, etc.), in the presence of an appropriate base (triethylamine etc.) at 0°-40° C.
Compounds of formulae (III), (VI), (VIII), (IX), (X), (XII), (XIV), (XV), (XVII), (XVIII) and (XX) may be prepared using a series of reactions depicted in the following schemes. ##STR39##
In the schemes,
R 9b is
(i) hydrogen,
(ii) phenyl,
(iii) C1-4 alkyl or
(iv) C1-4 alkyl substituted by one or two tings optionally selected from phenyl or 4-7 membered monocyclic hetero ring containing one nitrogen and/or one hydroxyl
R 9c has same meaning as R 9b provided that the hydroxy in R 9b is replaced by --OLi;
and the other symbols have the same meaning as hereinbefore defined;
PDC is pyridinium dichromate;
THP is tetrahydropyran-2-yl;
DMF is N,N-dimethylformamide;
THF is tetrahydrofuran;
HMPA is hexamethylphosphoramide;
TEA is triethylamine;
DBU is 1,8-diazabicyclo [5, 4, 0]-7-undecene;
DEAD is diethylazocarboxylate;
DHP is dihydropyran;
DME is dimethoxyethane; and
TBAB is n-tetrabutylammonium bromide.
In each reaction in the instant specification, products may be purified by conventional manner. For example, it may be carried out by a distillation at atmospheric or reduced pressure, high performace liquid chromatography, thin layer chromatography or column chromatography using silica gel or magnesium silicate, washing or recrystallization. Purification may be carried out after each reaction or after a series of reactions.
The starting materials and reagents in the processes for preparing the instant compounds are known per se, or may be prepared by methods known per se.
PHARMACOLOGIC ACTIVITIES
It has been confirmed that the compounds of the instant invention of formula (I) possess an agonistic activity at the PGI 2 receptor by the following experimental results.
i) Inhibitory activity on binding of [ 3 H]-iloprost to PGI 2 receptor in the human blood platelet membrane fraction
METHOD
50 mM Tris-HCl buffer (pH 7.4) containing 15 mM MgCl 2 , 5 mM EDTA and 10 nM [ 3 H]-iloprost were used as reaction medium. To 0.2 ml of the reaction medium, human blood platelet membrane fraction (0.3 mg protein) was added with or without a test compound. The mixture was incubated at 24° C. for 30 min. After incubation, 4 ml of ice-cold 10 mM Tris-HCl buffer (pH 7.4) was added to the reaction mixture, the mixture was filtered through Whatman GF/B glass fiber filter and washed 4 times with 4 ml of ice-cold 10 mM Tri-HCl buffer (pH 7.4) to separate bound and free [ 3 H]-iloprost. After washing, the filter was dried and radioactivity was counted. Non-specific binding was obtained by performing parallel binding experiments in the presence of 10 μM non-labelled iloprost. Specific binding was calculated by subtracting the non-specific binding from the total binding.
The inhibitory effect of a test compound was calculated from the following equation.
The percentage of inhibition (%)=100-(B 1 /B 0 ×100)
B 1 :specific [ 3 H]-iloprost binding in the presence of a test compound
B 0 :specific [ 3 H]-iloprost binding in the absence of a test compound
The results are shown in the following Table 1.
TABLE 1______________________________________Example No. IC.sub.50 (μM)______________________________________ 2 4.8 4 1.6 6 3.0 8(l) 1.5 8(n) 2.0 8(o) 0.4612 1.315 4.017 0.1517(b) 0.3617(c) 0.2717(i) 0.2217(n) 2.017(s) 0.7817(x) 5.017(cc) 0.2619 0.1221 4.423 1.5______________________________________
ii) Inhibitory effect on human blood platelet aggregation
METHOD
Platelet-rich plasma (PRP) was prepared from human blood (5×10 5 platelets/mm 3 ) and a test compound was added to PRP 1 minute prior to the addition of ADP (4 μm). The aggregation was monitored using a platelet aggregometer (NBS HEMA TRACER 601, Niko Bioscience, Japan).
The results are shown in the following Table 2.
TABLE 2______________________________________Example No. IC.sub.50 (μM)______________________________________ 4 3.7 8(n) 3.1 8(o) 0.9712 5.017 0.4217(b) 0.2417(c) 0.4717(s) 3.217(cc) 0.4119 0.1623 0.37______________________________________
TOXICITY
The toxicity of the compounds of the instant invention of formula (I) is very low and therefore, it may be confirmed that the compounds of the instant invention are fully safe for pharmaceutic use.
APPLICATION FOR PHARMACEUTICS
The compounds of the instant invention of formula (I) possess an agonistic activity on the PGI 2 receptor, and therefore are useful for the prevention and/or the treatment of thrombosis, arteriosclerosis, ischemic heart diseases, gastric ulcer, hypertension, etc.
For the purpose described above, the compounds of formula (I) of the instant invention, non-toxic salts thereof, acid additional salts thereof and hydrates thereof may be administered normally systemically or partially, usually by oral or parenteral administration.
The doses to be administered are determined depending on age, body weight, symptom, the desired therapeutic effect, the route of administration, the duration of the treatment etc. In the human adult, the doses per person per dose are generally between 1 mg and 1000 mg, by oral administration, up to several times per day, and between 100 μg and 100 mg, by parenteral administration up to several times per day, or continuous administration between 1 and 24 hrs. per day via a vein.
As mentioned above, the doses to be used depend on various conditions. Therefore, there are cases in which doses lower than or greater than the ranges specified above may be used.
When administering a compound of the instant invention, it is used as solid compositions, liquid compositions, other compositions for oral administration, as liniments, as suppositories etc. and for parenteral administration.
Solid compositions for oral administration include compressed tablets, pills, capsules, dispersible powders and granules. Capsules include hard capsules and soft capsules.
In such compositions, one or more of the active compound(s) is or are admixed with at least one inert diluent (such as lactose, mannitol, glucose, hydroxypropyl cellulose, microcrystalline cellulose, starch, polyvinylpyrrolidone, magnesium metasilicate aluminate etc.). The compositions also may comprise, as is normal practice, additional substances other than inert diluents: e.g. lubricating agents (such as magnesium stearate etc.) disintegrating agents (such as cellulose calcium glycolate, etc.), stabilizing agents (such as lactose, etc.) and assisting agents for dissolving such as glutamic acid etc.).
The tablets or pills may, if desired, be coated with a film of gastric or enteric material (such as sugar, gelatin, hydroxypropyl cellulose, hydroxypropylmethyl cellulose phtalate etc.), or may be coated with more than two films. Further coating may include containment within capsules of absorbable materials such as gelatin.
Liquid compositions for oral administration include pharmaceutically-acceptable solutions, emulsions, suspensions, syrups and elixirs. In such compositions, one or more of the acitve compound(s) is or are contained in inert diluent(s) commonly used in the art (Purified water, ethanol etc.). Besides inert diluents, such compositions also may comprise adjuvants (such as wetting agents, suspending agents etc.), sweetening agents, flavouring agents, perfuming agents and preserving agents.
Other compositions for oral administration included spray compositions which may be prepared by known methods and which comprise one or more of the active compound(s). Spray compositions may comprise additional substances other than inert diluents: e.g. stabilizing agents (sodium sulfate etc.), isotonic buffer(sodium chloride, sodium citrate, citric acid etc.). For preparation of such spray compositions, for example, the method described in U.S. Pat. No. 2,868,691 or 3,095,355 (herein incorporated in entirety by reference) may be used.
Injections for parenteral administration include sterile aqueous or non-aqueous solutions, suspensions and emulsions. In such compositions, one more of active compounds(s) is or are admixed with at least one of inert aqueous diluent(s) (distilled water for injection, physiological salt solution etc.) or inert non-aqueous diluent(s) (propylene glycol, polyethylene glycol, olive oil, ethanol, POLYSORBATE80 (registered trade mark) etc.).
Injections may comprise additional other inert diluents: e.g. preserving agents, wetting agents, emulsifying agents, dispersing agents, stabilizing agent (lactose, etc.), assisting agents such as assisting agents for dissolving (glutamic acid, asparaginic acid, etc.).
They may be sterilized for example, by filtration through a bacteria-retaining filter, by incorporation of sterilizing agents in the compositions or by irradiation. They also may be manufactured in the form of sterile solid compositions, for example, by freeze-drying, and which may be dissolved in sterile water or some other sterile diluent(s) for injection immediately before use.
Other compositions for parenteral administration include liquids for external use, endermic liniments, ointment, suppositories and pessaries which comprise one or more of the active compound(s) and may be prepared by per se known methods.
REFERENCE EXAMPLES AND EXAMPLES
The following reference examples and examples illustrate the instant invention, but do not limit the present invention.
The solvents in parentheses show the developing or eluting solvents and the ratios of the solvents used are by volume in chromatographic separations.
Unless otherwise specified, "IR" were measured by the liquid film method and "NMR" were measured in a solution of CDCl 3 .
Reference example 1
Methyl 3-(3-formylpropyl)phenoxyacetate ##STR40##
To a solution of oxalyl chloride (1.26 ml) in methylene chloride (30 ml) at -70° C., a solution of dimethylsulfoxide (2.11 ml) in methylene chloride (3.0 ml) was added dropwise. To the obtained solution, a solution of methyl 3-(4-hydroxybutyl) phenoxyacetate (1.94 g) in methylene chloride (8.0 ml) was added dropwise. Triethylamine (6.9 ml) was added dropwise thereto while the reaction temperature was maintained at -70° C. The reaction mixture was warmed slowly to -40° C. over a 30 min period and then quenched by addition of a saturated aqueous solution of ammonium chloride. The reaction mixture was extracted with ether. The extract was washed with a saturated aqueous solution of ammonium chloride and a saturated aqueous solution of sodium chloride, successively, dried over anhydrous magnesium sulfate and evaporated. The residue was purified by silica gel column chromatography (n-hexane:ethyl acetate=5:2) to give the title compound (1.41 g) having the following physical data.
TLC: Rf 0.26 (n-hexane:ethyl acetate=2:1);
NMR: δ9.74 (1H, s), 7.35-7.07(1H, m), 6.92-6.60 (3H, m), 4.62 (2H, s), 3.79 (3H, s), 2.63 (2H, t, J=7Hz), 2.47 (2H, t, J=8Hz), 2.10-1.92 (2H, m).
Reference example 2
Methyl 3-(4-hydroxyheptyl)phenoxyacetate ##STR41##
To a solution of the compound prepared in reference example 1 (1.26 g) in diethyl ether (10 ml), n-propylmagnesium bromide (3.0 ml of 2M in diethyl ether) was added dropwise at -70° C. The reaction mixture was stirred for 2 h with warming. After being quenched by addition of a saturated aqueous solution of ammonium chloride, the mixture was extracted with ether. The extract was washed with a saturated aqueous solution of sodium chloride, dried over anhydrous magnesium sulfate and evaporated. The residue was purified by silica gel column chromatography (n-hexane:ethyl acetate=2:1) to give the title compound (820 mg) having the following physical data.
TLC: Rf 0.23 (n-hexane:ethyl acetate=2:1);
NMR: δ7.36-7.08 (1H, m), 6.95-6.60 (3H, m), 4.64 (2H, s), 3.82 (3H, s), 3.80 -3.50 (1H, m), 2.80-2.36 (3H, m), 2.20-1.25 (8H, m), 1.10-0.80 (3H, m).
Reference example 3
Methyl 3-(4-oxoheptyl)phenoxyacetate ##STR42##
Pyridium dichromate (2.53 g) was added to a solution of the compound prepared in reference example 2 (750 mg) in dimethylformamide (10 ml) at room temperature. The mixture was stirred overnight. Celite (registered trade mark) and Florisil (registerd trade mark) were added to the mixture. The mixture was diluted with a mixture of n-hexane ethyl acetate (3:1)(20 ml). The mixture was filtered through Florisil and the filtrate was evaporated. The residue was purified by silica gel column chromatography (n-hexane: ethyl acetate=5:1) to give the title compound (350 mg) having the following physical data.
TLC: Rf 0.30 (n-hexane:ethyl acetate=3:1);
NMR: δ7.36-7.08 (1H, m), 6.90-6.60 (3H, m), 4.62 (2H, s), 3.81 (3H, s), 2.72-2.25 (6H, m), 2.10-1.38 (4H, m), 0.90 (3H, t, J=8Hz).
Reference example 4
3-[3-[2-(tetrahydropyran-2-yl)oxyethoxy]phenyl]propanol ##STR43##
To a suspension of sodium hydride (1.84 g, 60% dispersion) in dimethylformamide (50 ml) was added dropwise a solution of 3-(3-hydroxypropyl)phenol (7.0 g)in dimethylformamide (20 ml) at 0° C. The mixture was stirred for 1 h at room temperature. To the reaction mixture was added 1-bromo-2-(tetrahydropyran-2-yl)ethane (5.46 g) at 0° C. The mixture was stirred for 1 h at room temperature. After being quenched by addition of water, the mixture was extracted with ether. The extract was washed with 2N aqueous solution of sodium hydroxide, water and a saturated aqueous solution of sodium chloride, successively, dried over anhydrous magnesium sulfate and evaporated. The residue was purified by silica gel column chromatography (ethyl acetate:n-hexane=1:2→2:1) to give the title compound (3.36 g) having the following physical data.
TLC: Rf 0.17 (ethyl acetate:n-hexane=1:2);
IR(cm -1 ): ν3369, 2930, 1584, 1488, 1451, 1384, 1353, 1260, 1202, 1125, 1034, 992,874, 814, 777, 695.
Reference example 5
1-[2-(Tetrahydropyran-2-yl)oxyethoxy]-3-(3-hydroxy-4-diphenylamino sulfonylbutyl)benzene ##STR44##
To a solution of N,N-diphenylsulfonamide (0.99 g) in a mixture of tetrahydrofuran-hexamethylphosphoramide (20:3) (23 ml) was added dropwise n-butyllithium (3.75 ml of 1.6M in n-hexane) at -78° C. The mixture was stirred for 30 min at -78° C. To the mixture obtained was added a solution of a compound (which was prepared by the same procedure as reference example 1, using the compound prepared in reference example 4) (1.11 g) in tetrahydrofuran (10 ml). The reaction mixture was stirred for 1 h at -78° C. After quenched by addition of water, the mixture was extracted with ethyl acetate. The extract was washed with water and a saturated aqueous solution of sodium chloride, successively, dried over anhydrous magnesium sulfate and evaporated. The residue was purified by silica gel column chromatography (ethyl acetate:n-hexane=1:2) to give the title compound (0.84 g) having the following physical data.
TLC: Rf 0.37 (ethyl acetate:benzene=1:1);
IR(cm -1 ): ν3401, 3063, 2930, 1586, 1489, 1451, 1351, 1261, 1190, 1150, 1077, 1050, 1011, 969, 903, 822, 757, 697.
Reference example 6
1-[2-(Tetrahydropyran-2-yl )oxyethoxy]-3-(3-methylsulfonyloxy-4-diphenylaminosulfonylbutyl)benzene ##STR45##
To a solution of the compound prepared in reference example 5 (0.66 g) in methylene chloride (20 ml) were added successively triethylamine (0.305 g) and methanesulfonyl chloride (0.12 ml) at 0° C. The mixture was stirred for 10 min at same temperature. After quenched by addition of water, the mixture was extracted with ethyl acetate. The extract was washed with a saturated aqueous solution of ammonium chloride, water and a saturated aqueous solution of sodium chloride, successively, dried over anhydrous magnesium sulfate and evaporated. The residue containing the title compound having the following physical data. The residue was used for the next reaction without further purification.
TLC: Rf 0.31 (ethyl acetate:benzene=1:8).
Reference example 7
1-[2-(Tetrahydropyran-2-yl)oxyethoxy]-3-(4-diphenylaminosulfonyl-3-butenyl)benzene ##STR46##
To a solution of the residue obtained in reference example 6 in benzene was added 1, 8-diazabicyclo[5, 4, 0]-7-undecene (0.382 g) at 0° C. The mixture was stirred for 10 min at 0° C. After quenched by addition of water, the mixture was extracted with ethyl acetate. The extract was washed with a saturated aqueous solution of ammonium chloride, water and a saturated aqueous solution of sodium chloride, successively, dried over anhydrous magnesium sulfate and evaporated to give the title compound (0.63 g) having the following physical data.
TLC: Rf 0.27 (ethyl acetate:benzene=1:8);
IR (cm- -1 ): ν3063, 2943, 2873, 1734, 1586, 1489, 1451, 1354, 1260, 1152, 1126, 1076, 1034, 989, 969, 904, 874, 816,757, 697.
Reference example 8
2-[3-(4-Diphenylaminosufonyl-3-butenyl)phenoxy]ethanol ##STR47##
To a solution of the compound prepared in reference example 7 (0.541 g) in methanol (20 ml) was added a catalytic amount of 10-camphorsulfonic acid (dl form) at room temperature. The mixture was stirred for 1 h at room temperature. To the reaction mixture was added triethylamine (0.1 ml) the mixture was evaporated. The residue was purified by silica gel column chromatography (ethyl acetate:n-hexane=1:2→1:1) to give the title compound (0.404 g) having the following physical data.
TLC: Rf 0.37 (ethyl acetate:benzene=1:1);
IR(cm- -1 ): ν3401, 3063, 2930, 1586, 1489, 1451, 1351, 1261, 1190, 1150, 1077, 1050, 1011, 969, 903, 822, 757, 697.
Reference example 9
Methyl 3-(3-bromopropyl)phenoxyacetate ##STR48##
To a stirred solution of methyl 3-(3-hydroxypropyl)phenoxyacetate (2.00 g) in methylene chloride (20 ml) were added successively triphenylphosphine (2.81 g) and tetrabromomethane (3.55 g) at room temperature. The mixture was evaporated. The residue was purified by silica gel column chromatography (n-hexane:ethyl acetate=7:1) to give the title compound (1.69 g) having the following physical data.
TLC: Rf 0.26 (n-hexane:ethyl acetate=2:1);
NMR: δ7.30-7.06 (1H, m), 6.90-6.60 (3H, m), 4.63 (2H, s), 3.81 (3H, s), 3.38 (2H, t, J=8Hz), 2.76 (2H, t, J=8Hz), 2.32-1.96 (2H, m).
Reference example 10
1-Benzyloxy-3-(3-benzyloxycarbonylpropyl)benzene ##STR49##
A mixture of 1-hydroxy-3-(3-benzyioxycarbonylpropyl)benzene (2.0 g), benzylbromide (1.14 ml), potassium bicabonate (1.53 g) and dimethylformamide (20 ml) was stirred for 3 h at room temperature. The mixture was quenched by addition of water and extracted with a mixture of n-hexane:ethyl acetate (3:1). The extract was washed with water and a saturated aqueous solution of sodium chloride, successively, dried over anhydrous magnesium sulfate and evaporated. The residue was purified by silica gel column chromatography (n-hexane:ethyl acetate=10:1) to give the title compound (2.55 g) having the following physical data.
TLC: Rf 0.33 (n-hexane:ethyl acetate=7:1);
IR(cm -1 ): ν3065, 3033, 2939, 2866, 1734, 1583, 1489, 1455, 1382, 1315, 1258, 1156, 1082, 1027, 908, 850, 777, 739.
Reference example 11
4-(3-Benzyloxyphenyl)butanoic acid ##STR50##
To a solution of the compound prepared in reference example 10 (2.42 g) in a mixture of tetrahydrofuran-methanol (2:1) (20 ml) was added 2N aqueous solution of sodium hydroxide (11 ml) at 0° C. The mixture was stirred for 3 h at room temperature. After neutralized by addition of 2N aqueous solution of hydrochloric acid, the mixture was extracted with ethyl acetate. The extract was washed with water and a saturated aqueous solution of sodium chloride, successively, dried over anhydrous magnesium sulfate and evaporated. The residue was recrystallized from n-hexane-ethyl acetate to give the title compound (1.5 g) having the following physical data.
mp.: 100.0°-102.0° C.;
TLC: Rf 0.53 (ethyl acetate);
NMR: δ7.50-7.08 (7H, m), 6.93-6.70 (3H, m), 5.04 (2H, s), 2.66 (2H, t, J=7Hz), 2.36 (2H, t, J=8Hz), 2.16-1.93 (2H, m).
Reference example 12
1-Benzyloxy-3-[3-(N-methyl-N-methoxyamino)carbonylpropyl]benzene ##STR51##
An ethyl chloroformate (0.96 ml) was dissolved with stirring of a solution of the compound prepared in reference example 11 (2.45 g) and triethylamine (1.35 ml) in methylene chloride (30 ml) at -10° C. After stirred for 10 min at room temperature, to the mixture were added successively triethylamine (2.8 ml) and N-methyl-N-methoxyamine hydrochloride (980 mg) at -10° C. The mixture was stirred further for 1 h at room temperature and was poured into water. The mixture was extracted with a mixture of n-hexane-ethyl acetate (1:1). The extract was washed with water and a saturated aqueous solution of sodium chloride, successively, dried over anhydrous magnesium sulfate and evaporated. The residue was purified by silica gel column chromatography (n-hexane:ethyl acetate=2:1) to give the title compound (2.67 g) having the following physical data.
TLC: Rf 0.23 (n-hexane:ethyl acetate=2:1);
NMR: δ7.48-7.03 (6H, m), 6.86-6.67 (3H, m), 5.04 (2H, s), 3.61 (3H, s), 3.16 (3H, s), 2.78-2.30 (4H, m), 2.12-1.80 (2H, m).
Reference example 13
1-Benzyloxy-3-(3-hydroxy-3,3-diphenyl-1-propynyl)carbonylpropyl benzene ##STR52##
To a solution of 1,1-diphenyl-2-propyn-1-ol (3.89 g) in tetrahydrofuran (40 ml) was added n-butyllithium (23.4 ml of 1.6M in n-hexane) at -78° C. After being stirred for 30 min at the same temperature, to the mixture was added boron trifluoride etherate (5.05 ml). The mixture was stirred for 30 min at -78° C. To the mixture, the compound prepared in reference example 12 (2.67 g) in tetrahydrofuran (20 ml) was added at same temperature. After being stirred for 1 h at -78° C., the reaction mixture was quenched by addition of a saturated aqueous solution of ammonium chloride and the mixture stirred for 30 rain at room temperature. The mixture was extracted with a mixture of n-hexane-ethyl acetate (3:1). The extract was washed with water and a saturated aqueous solution of sodium chloride, successively, dried over anhydrous magnesium sulfate and evaporated. The residue was purified by silica gel column chromatography (n-hexane:ethyl acetate=7:1) to give the title compound (2.8 g) having the following physical data.
mp.: 54.5°-56.0° C.
TLC: Rf 0.18 (n-hexane:ethyl acetate=6:1);
NMR: δ7.45-7.10 (16H, m), 6.86-6.71 (3H, m), 5.01 (2H, s), 3.00 (1H, s), 2.68 -2.53 (4H, m), 2.10-1.90 (2H, m).
Reference example 14
1-Benzyloxy-3-[3-(5-hydroxydiphenylmethylisoxazole-3-yl)propyl]benzene ##STR53##
A mixture of the compound prepared in reference example 13 (1.0 g), hydroxyamine hydrochloride (1.5 g), pyridine (10 ml) and ethanol (10 ml) was refluxed for 6 h. The mixture was concentrated under reduced pressure and the reside was quenched by addition of water. The mixture was extracted with ethyl acetate. The extract was washed with a saturated aqueous solution of sodium chloride, dried over anhydrous magnesium sulfate and evaporated. The residue was purified by silica gel column chromatography (n-hexane:ethyl acetate=7:1) to give the title compound (940 mg) having the following physical data.
mp.: 89.0°-90.5° C.;
NMR: δ7.43-7.16 (16H, m), 6.80-6.74 (3H, m), 5.80 (1H, s), 5.03 (2H, s), 3.17 (1H, s), 2.67-2.61 (4H, m), 2.00-1.90 (2H, m).
Reference example 15
1-Benzyloxy-3-[3-(5-diphenylmethylisoxazol-3-yl)propyl]benzene ##STR54##
To a solution of the compound prepared in reference example 14 (860 mg) in trifluoroacetic acid (8.0 ml) was added a solution of triethylsilane (440 mg) in methylene chloride (2.0 ml) with stirring at 0° C. After stirring for 30 min at room temperature, the mixture was concentrated under reduced pressure. The residue was neutralized with a saturated aqueous solution of sodium bicarbonate and extracted with ethyl acetate. The extract was washed with water and a saturated aqueous solution of sodium chloride, successively, dried over anhydrous magnesium sulfate and evaporated. The residue was purified by silica gel column chromatography (n-hexane:ethyl acetate=8:1) to give the title compound (640 mg) having the following physical data.
TLC: Rf 0.50 (n-hexane:ethyl acetate=3:1);
NMR: δ7.50-7.00 (16H, m), 6.85-6.65 (3H, m), 5.70 (1H, s), 5.30 (1H, s), 5.03 (2H, s), 2.80-2.50 (4H, m), 2.17-1.75 (2H, m).
Reference example 16
1-Hydroxy-3-[3-(5-diphenylmethylisoxazol-3-yl)propyl]benzene ##STR55##
To a solution of the compound prepared in reference example 15 (550 mg) in methylene chloride (6.0 ml) was added boron tribromide (0.34 ml) with stirring at 0° C. The mixture was stirred for 30 min at 0° C., poured into ice water and extracted with ethyl acetate. The extract was washed with water and a saturated aqueous solution of sodium chloride, successively, dried over anhydrous magnesium sulfate and evaporated. The residue was purified by silica gel column chromatography (n-hexane:ethyl acetate=5:1→3:1) to give the title compound (376 mg) having the following physical data.
mp.: 114.5°-117° C.;
TLC: Rf 0.22 (n-hexane:ethyl acetate=3:1);
NMR: δ7.39-7.05 (11H, m), 6.75-6.60(3H, m), 5.73 (1H, s), 5.62-5.53 (1H, m), 5.52 (1H, s), 2.70-2.52 (4H, m), 2.02-1.84 (2H, m).
Reference example 17
Methyl 3-[3-[(1-amino-2, 2-diphenylethylidene)aminooxycarbonyl]propyl]phenoxyacetate ##STR56##
A suspension of 4-(3-methoxycarbonylmethoxyphenyl)butanoic acid (289 mg) and thionyl chloride (5.0 ml) was refluxed for 1 h. The mixture was cooled to room temperature and concentrated under reduced pressure. To a suspension of the residue and 1,1-diphenyl-2-amino-2-hydroxyiminoethane (285 mg)in methylene chloride (5 ml) was added tiethylamine (0.32 ml) with stirring at room temperature. The mixture was stirred overnight at room temperature. After quenched by addition of water, the mixture was extracted with ether. The extract was washed with water and a saturated aqueous solution of sodium chloride, successively, dried over anhydrous magnesium sulfate and evaporated. The residue was purified by silica gel flash chromatography (n-hexane:ethyl acetate=1:1) to give the title compound (193 mg) having the following physical data.
NMR: δ7.40-7.00 (11H, m), 6.90-6.50 (3H, m), 5.26 (1H, s), 4.75 (2H, brs), 4.58 (2H, s), 3.78 (3H, s), 2.64 (2H, t, J=7Hz), 2.40 (2H, t, J=7Hz), 2.00 (2H, m);
MS (m/z): 461 (M + +1).
Reference example 18
Methyl 3-(3-cyanopropyl)phenoxyacetate ##STR57##
A mixture of potassium cyanide (1.16 g), 18-crown-6 (236 mg) and acetonitrile (18 ml) was stirred for 15 min under an atmosphere of argon. A mixture of methyl 3-(3-hydroxypropyl)phenoxyacetate (2.0 g) and tributylphosphine (1.99 g)in acetonitrile (10 ml) was added to the reaction mixture, followed by the dropwise addition of a solution of carbon tetrachloride (0.95 ml) in an acetonitrile (10 ml) with cooling in ice bath. The mixture was stirred overnight at room temperature. The mixture was diluted with ether and washed with aqueous 10% citric acid. After the addition of carbon tetrachloride (10 ml), the mixture was washed with water and a saturated aqueous solution of sodium chloride, successively, dried over anhydrous magnesium sulfate, and evaporated. The reside was purified by silica gel column chromatography (ethyl acetate:n-hexane=9:1) to give the title compound (1.47 g) having the following physical data.
NMR: δ7.20 (1H, t, J=7Hz), 6.90-6.60 (3H, m), 4.60 (2H, s), 3.80 (3H, s), 2.74 (2H, t, J=7Hz), 2.30(2H, t, J=7 Hz), 1.98(2H, m).
Reference example 19
Methyl 3-(4-amino-4-hydroxyiminobutyl)phenoxyacetate ##STR58##
To a mixture of ethanol-water (5:1) (30 ml) were added successively the compound prepared in reference example 18 (1.01 g), hydroxyamine hydrochloride (331 mg) and sodium acetate (391 mg). The mixture was refluxed overnight. The mixture was concentrated under reduced pressure, and the residue was purified by silica gel column chromatography (n-hexane:ethyl acetate=1:1) to give the title compound (150 mg) having the following physical data.
NMR: δ7.13 (1H, t, J=7 Hz), 6.90-6.50 (3H, m), 5.10 (3H, brs), 4.60 (2H, s), 3.80 (3H, s), 2.63 (2H, t, J=7 Hz), 2.37 (2H, t, J=7 Hz), 1.95 (2H, m).
Reference example 20
Methyl 3-(4-amino-4-diphenylmethylcarbonyloxyiminobutyl)phenoxy acetate ##STR59##
A suspension of diphenylacetic acid (252 mg) and thionyl chloride (5.0 ml) was refluxed for 1 h. The mixture was cooled to room temperature and concentrated under reduced pressure. To a solution of the residue and the compound prepared in reference example 19 (144 mg) in methylene chloride (5.0 ml) was added triethylamine (0.33 ml) at room temperature. The mixture was stirred overnight at room temperature quenched by addition of water, and extracted with ether. The extract was washed with water and a saturated aqueous solution of sodium chloride, successively, dried over anhydrous magnesium sulfate and evaporated. The residue was purified by silica gel flash chromatography (n-hexane:ethyl acetate=1:1) to give the title compound (61 mg) having the following physical data.
NMR: δ7.40-7.00 (11H, m), 6.90-6.50 (3H, m), 5.10 (1H, s), 4.58 (2H, s), 3.79 (3H, s), 2.60 (2H, m), 2.21 (2H, m), 1.90 (2H, m);
MS (m/z): 461 (M + +1).
Reference example 21
1 -(5,5-Dibromo-4-pentenyl)-3-methoxybenzene ##STR60##
To a solution of carbon tetrabromide (16.7 g)in methylene chloride (35 ml) was added triphenyiphosphine (26.0 g) in methylene chloride (35 ml) at 0° C. and the mixture was stirred for 10 min. To the mixture was added a solution of 1-(3-formylpropyl)-3-methoxybenzene (3.00 g) in methylene chloride (20 ml) at 0° C. The mixture was stirred for 30 min at 0° C. To the mixture was added gradually n-hexane and the mixture was filtered to remove triphenylphosphineoxide. The filtrate was washed with water and a saturated aqueous solution of sodium chloride, successively, dried over anhydrous magnesium sulfate and evaporated. The residue was purified by silica gel column chromatography (n-hexane:ethyl acetate=24:1) to give the title compound (5.33 g) having the following physical data.
MS (m/z): 334 (M + ).
TLC: Rf 0.34 (n-hexane:ethyl acetate=24:1).
Reference example 22
1-(4-pentynyl)-3-methoxybenzene ##STR61##
To a solution of the compound prepared in reference example 21 (3.58 g) in THF (40 ml) was added dropwise n-butyllithium (14.7 ml; 1.6M/L in hexane solution) at -70° C. The mixture was stirred for 30 min at -70° C. After quenched by addition of water and aqueous solution of ammonium chloride at the same temperature, the mixture was warmed up to room temperature. The mixture was extracted with n-hexane - ethyl acetate (6:1). The extract was washed with water and a saturated aqueous solution of sodium chloride, successively dried over anhydrous magnesium sulfate, and evaporated. The residue was purified by silica gel column chromatography (n-hexane:ethyl acetate=24:1) to give the title compound (1.86 g) having the following physical data.
TLC: Rf 0.32 (n-hexane:ethyl acetate=24:1);
IR(cm- -1 ): ν3295, 2943, 2117, 1602, 1489, 1261.
Reference example 23
1-(7,7-Diphenyl-6-oxo-4-heptynyl)-3-methoxybenzene ##STR62##
To a mixture of ethylmagnesium bromide (3.4 ml; 3.0 M/L in ether solution) and THF (20 ml) was added dropwise a solution of the compound prepared in reference example 22 (1.5 g) in THF (15 ml) over a 10 min period. The mixture was stirred for 2 h at room temperature. To the mixture was added a solution of diphenylacetaldehyde (1.7 g) in THF (10 ml). The mixture was stirred for 2 h. After quenched by addition of ammonium chloride, the mixture was extracted with ether. The extract was washed with water and a saturated aqueous solution of sodium chloride, successively, dried over anhydrous magnesium sulfate and evaporated. To a solution of the residue in ether (40 ml) was added manganese (IV) oxide (2.0 g) at room temperature. The mixture was stirred for 2 h. The mixture was filtrated and evaporated. The residue was purified by silica gel column chromatography (n-hexane:ethyl acetate=7:1) to give the title compound (1.99 g) having the following physical data.
MS (m/z): 368 (M + ).
TLC: Rf 0.46 (n-hexane:ethyl acetate=3:1).
Reference example 24
1-(6-Imino-4-hydroxy-7,7-diphenyl-4-heptynyl)-3-methoxybenzene ##STR63##
A mixture of the compound (400 mg) prepared by the same procedure as reference example 14 using the compound prepared in reference example 23, Raney nickel (300 mg; registered trade mark) and ethanol (5 ml) was stirred overnight under an atmosphere of hydrogen. The mixture was filtered through Celite (registered trade mark) and evaporated. The residue was purified by silica gel column chromatography (ethyl acetate:benzene=7:93) to give the title compound (184 mg) having the following physical data.
MS (m/z): 385 (M + ).
TLC: Rf 0.26 (n-hexane:ethyl acetate=3:1).
Reference example 25
1-[3-(3-Diphenylmethylisothiazol-5-yl)propyl]-3-methoxybenzene ##STR64##
A mixture of the compound prepared in reference example 24 (121 mg), p-chloranil (77 mg), phosphorus pentasulfide (209 mg) and toluene (2 ml) was refluxed for 30 min. After cooled to room temperature, to the mixture was added benzene. The mixture was filtrated and evaporated. The residue was purified by silica gel column chromatography (n-hexane:ethyl acetate=6:1) to give the title compound (62 mg) having the following physical data.
MS (m/z): 399 (M + ).
TLC: Rf 0.30 (n-hexane:ethyl acetate=6:1).
EXAMPLE 1
Methyl 3-(4-diphenylmethyloxyiminobutyl)phenoxyacetate ##STR65##
To a solution of the compound prepared in reference example 1 (300 mg) in ethanol (10 ml) was added diphenylmethyloxyamine (253 mg) at room temperature. The mixture was stirred overnight at room temperature and concentrated under reduced pressure. The residue was purified by silica gel column chromatography (benzene:ethyl acetate=9:1) to give the title compound (520 mg) having the following physical data.
TLC: Rf 0.31 (n-hexane:ethyl acetate=4:1);
NMR: δ7.60-7.10 (12H, m), 6.90-6.80 (3H, m), 6.22 (1H, s), 4.60 (2H, s), 3.79 (3H, s), 2.8-2.00 (4H, m), 1.80 (2H, m).
EXAMPLE 2
3-(4-Diphenylmethyloxyiminobutyl)phenoxyacetic acid ##STR66##
To a solution of the compound prepared in example 1 (305 mg) in a mixture of dimethoxymethane (3.0 ml) and methanol (1.0 ml) was added 2N aqueous solution of sodium hydroxide (0.5 ml) at room temperature. After being stirred for 1 h, the mixture was quenched by addition of 1N hydrochloric acid (0.5 ml) and extracted with ethyl acetate. The extract was washed with water and a saturated aqueous solution of sodium chloride, successively, dried over anhydrous magnesium sulfate and evaporated. The residue was purified by silica gel column chromatography (ethyl acetate:n-hexane=1:1) to give the title compound (277 mg) having the following physical data.
MS (m/z): 403 (M + ), 381, 359, 345, 236, 219, 184, 168;
NMR: δ7.55 (1H, t, J=6 Hz), 7.40-7.10 (11H, m), 6.90-6.80 (3H, m), 6.20 (1H, s), 4.62 (2H, s), 2.80-2.40 (3H, m), 2.17 (1H, brs), 1.80 (2H, m).
EXAMPLE 2(a)-2(c)
By the same procedure as in example 2, using the compound prepared in the same procedure as in reference example 1→example 1 which was using corresponding phenoxyacetic acid derivative compound instead of methyl 3-(4-hydroxybutyl) phenoxyacetate, compounds having the following physical data shown in the table 3 were given.
TABLE 3__________________________________________________________________________EX.No. Structure of the example compound MS (m/z) IR.sub.(cm.spsb.-1.sub.)__________________________________________________________________________2 (a) ##STR67## 389(M.sup.+), 344, 222, 205, [KBr method] ν 3030, 2911, 1743, 1708, 1610, 1515, 1455, 1431, 1237, 1189, 1095, 1023, 919, 832, 746, 7052 (b) ##STR68## 403(M.sup.+), 360, 345, 236, 219, 184, 118, 152 ν 3030, 2927, 1736, 1611, 1586, 1510, 1454, 1301, 1218, 1180, 1081, 1022, 920, 830, 740, 702, 6092 (c) ##STR69## 390(M.sup.+ + 1) ν 3031, 2922, 1734, 1586, 1494, 1454, 1241, 1160, 1084, 1020, 919, 746, 700__________________________________________________________________________
The example compounds shown in table 3 are named as follows:
2(a) 4-(3-Diphenylmethyloxyiminopropyl)phenoxyacetic acid,
2(b) 4-(4-Diphenylmethyloxyiminobutyl)phenoxyacetic acid,
2(c) 3-(3-Diphenylmethyloxyiminopropyl)phenoxyacetic acid.
EXAMPLE 3
Methyl 3-(4-diphenylmethyloxyiminoheptyl)phenoxyacetate ##STR70##
By the same procedure as in example 1, using the compound prepared in reference example 3, the title compound having the following physical data was given.
TLC: Rf 0.35 (n-hexane:ethyl acetate=3:1);
IR (cm -1 ): ν3062, 3030, 2958, 2872, 1763, 1741, 1586, 1494, 1452, 1377, 1289, 1209, 1159, 1088, 1025, 937, 744, 700.
EXAMPLE 4
3-(4-Diphenylmethyloxyiminoheptyl)phenoxyacetic acid ##STR71##
By the same procedure as in example 2, using the compound prepared in example 3, the title compound having the following physical data was given.
TLC: Rf 0.20 (chloroform:methanol=4:1);
IR (cm -1 ): ν3031, 2961, 2872, 1737, 1587, 1494, 1454, 1375, 1241, 1160, 1086, 1042, 938, 763, 744, 700.
EXAMPLE 5
Methyl 3-(4-diphenylmethyloxyaminoheptyl)phenoxyacetate ##STR72##
To a solution of the compound prepared in example 3 (150 mg) in methanol (1 ml) was added sodium cyanoborohydride (82 mg) at room temperature. This solution was adjusted to pH 3 by addition of saturated hydrochloride in methanol and the mixture was stirred for 2 h at room temperature. After being neutralized by addition of a saturated aqueous solution of sodium bicarbonate, the mixture was extracted with ethyl acetate. The extract was washed with water and aqueous solution of sodium chloride, successively, dried over anhydrous magnesium sulfate and evaporated. The residue was purified by silica gel column chromatography (n-hexane:ethyl acetate=3:1) to give title compound (147 mg) having the following physical data.
TLC: Rf 0.34 (n-hexane:ethyl acetate=3:1);
IR (cm -1 ): ν3030, 2932, 2869, 1764, 1741, 1586, 1493, 1452, 1376, 1209, 1159, 1086, 1029, 888, 761, 743, 699.
EXAMPLE 6
3-(4-Diphenylmethyloxyaminoheptyl)phenoxyacetic acid ##STR73##
By the same procedure as example 2, using the compound prepared in example 5 (125 mg), the title compound (115 mg) having the following physical data was given.
TLC: Rf 0.21 (chloroform:methanol=4:1);
IR (cm -1 ): ν3031, 2932, 2871, 1738, 1586. 1494, 1454, 1374, 1241, 1159, 1082, 1046, 915, 762, 744, 698.
EXAMPLE 7
Methyl 3-(3,3-diphenylmethylpropyl)aminocarbonylmethyl)phenoxy acetate ##STR74##
A mixture of 3-methoxycarbonylmethoxyphenylacetic acid (150 mg), 2-chloro-N-methylpyridinium iodide (241 mg), 3,3-diphenylpropylamine (146 mg) and triethylamine (0.26 ml) in methylene chloride (7 ml) was stirred overnight at room temperature. The mixture was poured into 1N hydrochloric acid and extracted with ether. The extract was washed with water and a saturated aqueous solution of sodium chloride, successively, dried over anhydrous magnesium sulfate and evaporated. The residue was purified by silica gel column chromatography (ethyl acetate:methylene chloride=1:25) to give title compound (125 mg) having the following physical data.
TLC: Rf 0.33 (ethyl acetate:methylene chloride=1:9);
NMR: δ7.40-7.00 (11H, m), 6.90-6.70 (3H, m), 5.30 (1H, m), 4.63 (2H, s), 3.83 (1H, t, J=7Hz), 3.80 (3H, s), 3.47 (2H, s), 3.17 (2H, dt, J=8, 7Hz), 2.20 (2H, dt, J=5, 7Hz).
EXAMPLE 8
3-(3,3-diphenylpropyl)aminocarbonylmethyl)phenoxyacetic acid ##STR75##
By the same procedure as example 2, using the compound prepared in example 7 (119 mg), the title compound (98 mg) having the following physical data was given.
TLC: Rf 0.48 (methylene chloride:methanol=10:3);
IR (cm -1 ): ν3295, 3024, 2880, 2526, 1757, 1584, 1557, 1490, 1469, 1450, 1381, 1356, 1304, 1285, 1242, 1204, 1155, 1087, 1030, 958, 905, 880, 776, 753, 741, 697, 674, 638, 614, 588, 557, 482, 456, 431.
EXAMPLE 8(a)-8(cc)
By the same procedure as in example 7→example 2, using corresponding phenoxyacetic acid derivative compounds and corresponding amines, compounds having the following physical data shown in the table 4 were given.
TABLE 4__________________________________________________________________________EX.No. Structure of the example compound TLC IR (cm.sup.-1)__________________________________________________________________________8 (a)##STR76## Rf 0.50 (methylene chloride: methanol = 10:3) ν 3033, 1742, 1614, 1587, 1495, 1438, 1213, 1159, 1082, 1017, 780, 732, 7028 (b)##STR77## Rf 0.53 (methylene chloride: methanol = 10:3) ν 3436, 3031, 1742, 1603, 1494, 1452, 1363, 1221, 1160, 1083, 1029, 954, 775, 736, 7008 (c)##STR78## Rf 0.30 (methylene chloride: methanol = 10:3) [KBr method] ν 3268, 3057, 1724, 1636, 1588, 1561, 1492, 1453, 1432, 1400, 1368, 1348, 1314, 1283, 1259, 1231, 1172, 1158, 1093, 1080, 1026, 951, 919, 855, 787, 766, 744, 696, 618, 605, 557, 532, 4898 (d)##STR79## Rf 0.40 (methylene chloride: methanol = 10:3) [KBr method] ν 3297, 3058, 2917, 1719, 1703, 1653, 1613, 1589, 1531, 1494, 1451, 1434, 1412, 1359, 1341, 1277, 1237, 1161, 1085, 1032, 978, 752, 742, 702, 642, 6208 (e)##STR80## Rf 0.40 (methylene chloride: methanol = 10:3) [KBr method] ν 3273, 3038, 2916, 1753, 1674, 1590, 1516, 1494, 1460, 1431, 1315, 1276, 1241, 1163, 1098, 1085, 1030, 965, 877, 784, 752, 693, 626, 546, 5078 (f)##STR81## Rf 0.40 (methylene chloride: methanol = 10:3) [KBr method] ν 3318, 3063, 2921, 1752, 1646, 1586, 1540, 1495, 1440, 1255, 1165, 1100, 1028, 966, 914, 877, 760, 701, 5418 (g)##STR82## Rf 0.40 (methylene chloride: methanol = 10:3) [KBr method] ν 3309, 3028, 2912, 1724, 1625, 1604, 1580, 1494, 1435, 1299, 1246, 1160, 1087, 1013, 924, 886, 774, 756, 742, 704, 633, 585, 5428 (h)##STR83## Rf 0.38 (methylene chloride: methanol = 10:3) [KBr method] ν 3233, 3032, 2912, 1719, 1641, 1609, 1588, 1532, 1494, 1458, 1436, 1341, 1300, 1250, 1161, 1098, 1086, 1054, 985, 914, 888, 813, 764, 748, 698, 602, 574, 5318 (i)##STR84## Rf 0.40 (methylene chloride: methanol = 10:3) [KBr method] ν 3314, 3057, 1737, 1639, 1587, 1511, 1490, 1446, 1367, 1324, 1304, 1221, 1158, 1075, 1028, 1000, 972, 918, 879, 774, 695, 651, 628, 549, 4528 (j)##STR85## Rf 0.50 (methylene chloride: methanol = 10:3) ν 3351, 3027, 2933, 1734, 1713, 1603, 1558, 1494, 1452, 1364, 1227, 1160, 1089, 1031, 914, 776, 752, 7018 (k)##STR86## Rf 0.53 (methylene chloride: methanol = 10:3) ν 3033, 2930, 1742, 1611, 1586, 1495, 1453, 1413, 1357, 1267, 1208, 1158, 1079, 1017, 878, 777, 7008 (l)##STR87## Rf 0.53 (methylene chloride: methanol = 10:3) ν 3031, 2927, 1746, 1604, 1495, 1452, 1361, 1223, 1160, 1083, 1029, 953, 879, 783, 735, 6998 (m)##STR88## Rf 0.33 (methylene chloride: methanol = 10:3) [KBr method] ν 3320, 3031, 2952, 2587, 1737, 1641, 1611, 1580, 1541, 1485, 1461, 1423, 1377, 1349, 1297, 1279, 1239, 1165, 1103, 1030, 1009, 925, 877, 781, 770, 735, 6958 (n)##STR89## Rf 0.50 (methylene chloride: methanol = 10:3) [KBr method] ν 3320, 3034, 2948, 1750, 1644, 1586, 1532, 1495, 1459, 1426, 1377, 1304, 1258, 1243, 1212, 1164, 1100, 1032, 935, 873, 756, 698, 644, 6058 (o)##STR90## Rf 0.56 (methylene chloride: methanol = 10:3) [KBr method] ν 3279, 3027, 2932, 2587, 1744, 1669, 1591, 1518, 1495, 1430, 1383, 1329, 1256, 1206, 1174, 1094, 1031, 939, 923, 853, 782, 746, 698, 631, 5598 (p)##STR91## Rf 0.45 (methylene chloride: methanol = 10:3) [KBr method] ν 3344, 3031, 2944, 1746, 1640, 1603, 1523, 1495, 1454, 1419, 1244, 1168, 1090, 1031, 902, 785, 781, 702, 642, 584, 5388 (q)##STR92## Rf 0.47 (methylene chloride: methanol = 10:3) [KBr method] ν 3347, 2938, 2866, 2549, 1737, 1615, 1587, 1553, 1493, 1452, 1437, 1362, 1293, 1226, 1158, 1083, 1028, 908, 877, 790, 758, 704, 630, 587, 5438 (r)##STR93## Rf 0.44 (methylene chloride: methanol = 10:3) [KBr method] ν 3205, 2930, 1736, 1655, 1586, 1494, 1452, 1229, 1160, 1082, 1023, 875, 762, 746, 6988 (s)##STR94## Rf 0.50 (methylene chloride: methanol = 10:3) [KBr method] ν 3482, 3159, 3053, 2965, 2905, 2759, 2524, 1746, 1637, 1584, 1489, 1457, 1432, 1397, 1359, 1322, 1309, 1272, 1229, 1156, 1087, 1028, 956, 927, 873, 774, 741, 695, 637, 600, 523, 463, 4318 (t)##STR95## Rf 0.32 (methylene chloride: methanol = 10:3) [KBr method] ν 3326, 3023, 2920, 2880, 1719, 1585, 1494, 1484, 1451, 1435, 1378, 1312, 1293, 1249, 1208, 1168, 1091, 894, 865, 785, 770, 750, 696, 606, 585, 495, 4688 (u)##STR96## Rf 0.49 (methylene chloride: methanol = 10:3) ν 3031, 2931, 1746, 1613, 1587, 1495, 1454, 1416, 1266, 1211, 1159, 1082, 1018, 883, 778, 756, 7008 (v)##STR97## Rf 0.53 (methylene chloride: methanol = 10:3) ν 3030, 2927, 1746, 1603, 1494, 1452, 1361, 1217, 1161, 1082, 1029, 1002, 956, 883, 752, 6998 (w)##STR98## Rf 0.21 (methylene chloride: methanol = 10:3) [KBr method] ν 3347, 3293, 3033, 2935, 1742, 1712, 1640, 1610, 1587, 1547, 1492, 1454, 1432, 1350, 1301, 1281, 1213, 1159, 1104, 1080, 1020, 922, 887, 781, 749, 695, 498, 4568 (x)##STR99## Rf 0.43 (methylene chloride: methanol = 10:3) [KBr method] ν 3326, 3061, 1752, 1651, 1614, 1585, 1535, 1496, 1455, 1427, 1381, 1299, 1246, 1220, 1166, 1106, 980, 922, 874, 789, 769, 745, 697, 640, 5328 (y)##STR100## Rf 0.40 (methylene chloride: methanol = 10:3) [KBr method] ν 3279, 1737, 1704, 1673, 1589, 1523, 1496, 1453, 1414, 1301, 1280, 1234, 1160, 1086, 921, 771, 747, 693, 630, 5078 (z)##STR101## Rf 0.38 (methylene chloride: methanol = 10:3) [KBr method] ν 3328, 3063, 3030, 2916, 2582, 1752, 1641, 1595, 1537, 1495, 1455, 1432, 1319, 1300, 1251, 1175, 1094, 1030, 913, 847, 790, 759, 699, 644, 539, 5088 (aa)##STR102## Rf 0.50 (methylene chloride: methanol = 10:3) [KBr method] ν 3339, 3060, 2931, 1737, 1603, 1561, 1494, 1452, 1224, 1159, 1087, 1032, 1008, 881, 783, 755, 742, 701, 586, 5408 (bb)##STR103## Rf 0.33 (methylene chloride: methanol = 10:3) [KBr method] ν 3209, 3032, 1736, 1656, 1494, 1452, 1229, 1161, 1084, 1002, 876, 762, 746, 6998 (cc)##STR104## RF 0.48 (methylene chloride: methanol = 10:3) [KBr method] ν 3181, 3070, 3025, 2924, 2524, 1736, 1631, 1584, 1490, 1460, 1440, 1397, 1335, 1313, 1284, 1265, 1232, 1159, 1113, 1094, 1030, 958, 929, 912, 881, 783, 772, 736, 691, 637, 612, 597, 545, 470, 443__________________________________________________________________________
The example compounds shown in table 4 are named as follows:
8(a) 3-(N-Benzyl-N-phenylaminocarbonylmethyl)phenoxyacetic acid,
8(b) 3-(N,N-Dibenzylaminocarbonylmethyl)phenoxyacetic acid,
8(c) 3-(N-Benzylaminocarbonylmethyl)phenoxyacetic acid,
8(d) 3-(Diphenylmethylaminocarbonylmethyl)phenoxyacetic acid,
8(e) 3-[(N,N-Diphenylamino )aminocarbonylmethyl]phenoxyacetic acid.
8(f) 3-[(1,2-Diphenylethylaminocarbonylmethyl)phenoxyacetic acid,
8(g) 3-(2,2-Diphenylethylaminocarbonylmethyl)phenoxyacetic acid,
8(h) 3-(Diphenylmethyloxyaminocarbonylmethyl)phenoxyacetic acid,
8(i) 3-[(1,1-Diphenylmethylideneamino)aminocarbonylmethyl]phenoxyacetic acid,
8(j) 3-[3-(3,3-Diphenylpropylaminocarbonyl)propyl]phenoxyacetic acid,
8(k) 3-[3-(N-Benzyl-N-phenylaminocarbonyl)propyl]phenoxyacetic acid,
8(l) 3-[3-(N,N-Dibenzylaminocarbonyl)propyl]phenoxyacetic acid,
8(m) 3-(3-Benzylaminocarbonylpropyl)phenoxyacetic acid,
8(n) 3-(3-Diphenylmethylaminocarbonylpropyl)phenoxyacetic acid,
8(o) 3-[3-[(N,N-Diphenylamino)aminocarbonyl]propyl]phenoxyacetic acid,
8(p) 3-[3-(1,2-Diphenylethylaminocarbonyl)propyl]phenoxyacetic acid,
8(q) 3-[3-(2,2-Diphenylethylaminocarbonyl)propyl]phenoxyacetic acid,
8(r) 3-(3-Diphenylmethyloxyaminocarbonylpropyl)phenoxyacetic acid,
8(s) 3-[3-[(1,1-Diphenylmethylideneamino)aminocarbonyl]propyl]phenoxy acetic acid,
8(t) 3-[2-(3,3-Diphenylpropylaminocarbonyl)ethyl]phenoxyacetic acid,
8(u) 3-[2-(N-Benzyl-N-phenylaminocarbonyl)ethyl]phenoxyacetic acid,
8(v) 3-[2-(N,N-Dibenzylaminocarbonyl)ethyl]phenoxyacetic acid,
8(w) 3-(2-Benzylaminocarbonylethyl)phenoxyacetic acid,
8(x) 3-(2-Diphenylmethylaminocarbonylethyl)phenoxyacetic acid,
8(y) 3-[2-[(N,N-Diphenylamino)aminocarbonyl]ethyl]phenoxyacetic acid.
8(z) 3-[2-(1,2-Diphenylethylaminocarbonyl)ethyl]phenoxyacetic acid,
8(aa) 3-[2-(2,2-Diphenylethylaminocarbonyl)ethyl]phenoxyacetic acid,
8(bb) 3-(2-Diphenylmethyloxyaminocarbonylethyl)phenoxyacetic acid and
8(cc) 3-[2-[(1,1-Diphenylmethylideneamino)aminocarbonyl]ethyl]phenoxy acetic acid.
EXAMPLE 9
3-(4-Diphenylaminosulfonyl-3-butenyl)phenoxyacetic acid ##STR105##
To a solution of the compound (0.08 g) prepared by the same procedure as in reference example 1, using the compound prepared in reference example 8, in acetone (2.0 ml) was added 8N Jone's reagent (0.1 ml) at 0° C. After stirring for 10 min at 0° C., to the mixture was added isopropyl alcohol (0.5 ml). The mixture was stirred for 10 min, water was added and the mixture was extracted with ether. The extract was washed with water and a saturated aqueous solution of sodium chloride, successively, dried over anhydrous magnesium sulfate and evaporated. The residue was purified by silica gel column chromatography (methylene chloride→methylene chloride:methanol=40:1) to give the title compound (0.035 g) having the following physical data.
TLC: Rf 0.18 (methylene chloride:methanol=5:1);
IR [KBr tablet method] (cm -1 ): ν3435, 3051, 2928, 1749, 1714, 1611, 1586, 1489, 1452, 1424, 1353, 1262, 1224, 1193, 1164, 1147, 1091, 1027, 1011, 975, 912, 865, 824, 781, 757, 694, 631, 596, 547.
EXAMPLE 10
3-(4-Diphenylaminosulfonylbutyl)phenoxyacetic acid ##STR106##
To a solution of the compound prepared in example 9 (410 mg) in ethyl acetate (5.0 ml) was added an excess amount of diazomethane in ether at 0° C. After 10 min, the mixture was evaporated. The residue was purified by silica gel column chromatography (n-hexane:ethyl acetate=2:1) to give a methyl ester compound (56 mg). To a solution of the methyl ester compound (56 mg) in methanol (5 ml) was added 10% palladium on activated carbon (50 mg) at room temperature. The mixture was stirred vigorously for 6 h under an atmosphere of hydrogen. The catalyst was removed by filtration through Celite. Evaporation of the solvent gave (54 mg) of the residue. By the same procedure as in example 2, using the residue, the title compound (36 mg) having physical data was given.
TLC: Rf 0.21 (methylene chloride:methanol=5:1);
IR [KBr tablet method] (cm -1 ): ν2925, 2862, 2590, 1750, 1710, 1612, 1586, 1488, 1463, 1451, 1424, 1350, 1302, 1287, 1258, 1243, 1218, 1197, 1164, 1146, 1103, 1078, 1027, 1012, 978, 913, 865, 780, 759, 708, 695, 626, 594, 534.
EXAMPLE 11
Methyl 3-(4-diphenylmethyloxybutyl)phenoxyacetate ##STR107##
To a solution of methyl 3-(4-hydroxybutyl)phenoxyacetate (372 mg) and diphenylmethyltrichloroacetoimidate (771 mg) in chloroform (4 ml) and cyclohexane (8 ml) was added a catalytic amount of boron trifluoride etherate at 0° C. After being stirred for 30 min at 0° C., the mixture was quenched by addition of a saturated aqueous solution of sodium bicarbonate and extracted with ether. The extract was washed with water and a saturated aqueous solution of sodium chloride, successively, dried over anhydrous magnesium sulfate and evaporated. The residue was purified by silica gel column chromatography (n-hexane:ethyl acetate=4:1) to give the title compound (343 mg) having the following physical data.
NMR: δ7.50-7.00 (11H, m), 6,90-6.50 (3H, m), 5.27 (1H, s), 4.58 (2H, s), 3.77 (3H, s), 3.43 (2H, t, J=7Hz), 2.58 (2H, t, J=7Hz), 1.68 (4H, m);
IR (cm -1 ): ν3029, 2938, 2860, 1762, 1586, 1494, 1453, 1211, 1159, 1095, 1029, 743,699.
EXAMPLE 12
3-(4-Diphenylmethyloxybutyl)phenoxyacetic acid ##STR108##
By the same procedure as in example 2, using the compound prepared in example 11 (340 mg), the title compound (277 mg) having the following physical data was given.
TLC: Rf 0.18 (chloroform:methanol=9:1);
IR (cm -1 ): ν3030, 2938, 2862, 1733, 1586, 1494, 1454, 1242, 1160, 1094, 761, 744, 699.
EXAMPLE 12(a)
3-(3-Diphenylmethyloxypropyl)phenoxyacetic acid ##STR109##
By the same procedure as in example 11→example 2, using methyl 3-(3-hydroxypropyl)phenoxyacetate instead of methyl 3-(4-hydroxybutyl) phenoxycacetate, the title compound having the following physical data was given.
mp.: 110°-112° C.;
TLC: Rf 0.15 (ethyl acetate);
IR [KBr tablet method] (cm -1 ): ν2861, 1748, 1710, 1594, 1494, 1431, 1398, 1307, 1237, 1174, 1105, 1083, 1059, 1030, 904, 859, 783, 741, 697, 651, 612.
EXAMPLE 13
Methyl 3-(4-triphenylmethoxybutyl)phenoxyacetate ##STR110##
To a solution of methyl 3-(4-hydroxybutyl) phenoxyacetate (174 mg) in dimethylformamide (8.0 ml) was added successively trityl chloride (223 mg) and N,N-dimethylaminopyridine (88 mg). After stirred overnight at room temperature, the mixture was quenched by addition of water and extracted with ether. The extract was washed with water and a saturated aqueous solution of sodium chloride, successively, dried over anhydrous magnesium sulfate and evaporated. The residue was purified by flash silica gel chromatography (n-hexane:ethyl acetate=4:1) to give the title compound (228 mg) having the following physical data.
NMR: δ7.50-7.00 (16H, m), 6.90-6.50 (3H, m), 4.58 (2H, s), 3.78 (3H, s), 3.04 (2H, t, J=7Hz), 2.53 (2H, m), 1.66 (4H, m);
IR (cm -1 ): ν3057, 2938, 2865, 1764, 1741, 1586, 1490, 1449, 1289, 1211, 1158, 1075, 1033, 764, 707.
EXAMPLE 14
3-(4-Triphenylmethoxybutyl)phenoxyacetic acid ##STR111##
By the same procedure as in example 2, using the compound prepared in example 13 (220 mg), the title compound (159 mg) having the following physical data was given.
TLC: Rf 0.13 (chloroform:methanol=9:1);
IR (cm -1 ): ν3058, 2937, 2866, 1738, 1586, 1490, 1449, 1240, 1159, 1075, 900, 764, 698.
EXAMPLE 15
Methyl 3-(3-diphenylmethyloxycarbonylpropyl)phenoxyacetate ##STR112##
A mixture of 3-(3-methoxycarbonylmethoxyphenyl)propionic acid (195 mg), 2-chloro-N-methylpyridinium iodide (297 mg), diphenylmethanol (185 mg), triethylamine (0.32 ml), and catalytic amount of N,N-dimethyaminopyridine in methylene chloride (6 ml) was stirred overnight at room temperature. The mixture was poured into 1N hydrochloric acid extracted with ethyl acetate. The extract was washed with water and saturated aqueous solution of sodium chloride, successively, dried over anhydrous magnesium sulfate and evaporated. The residue was purified by silica gel column chromatography (n-hexane:ethyl acetate=4:1) to give the title compound (128 mg) having the following physical data.
TLC: Rf 0.54 (n-hexane:ethyl acetate=7:3);
NMR: δ7.40-7.10 (11H, m), 6.89 (1H, s), 6.85-6.60 (3H, m), 4.60 (2H, s), 3.79 (3H, s), 2.60 (2H, t, J=6 Hz), 2.43 (2H, t, J=7 Hz), 1.97 (2H, m).
EXAMPLE 16
Methyl 3-[3-(4-diphenylmethylpyrazol-1-yl)propyl]phenoxyacetate ##STR113##
To a suspension of sodium hydride (217 mg, 60% dispersion) in dimethylformamide (10 ml) was added dropwise a solution of 4-diphenylmethylpyrazole (1.27 g) in dimethylformamide (50 ml) at room temperature. After being stirred for 30 min at room temperature, to the mixture was added dropwise a solution of the compound prepared in reference example 9(1.56 g) in dimethylformamide. After being stirred for 1 h, the mixture was quenched by addition of 1N hydrochloric acid and extracted with a mixture of ethyl acetate-n-hexane (1:2). The extract was washed with saturated aqueous solution of sodium chloride, dried over anhydrous magnesium sulfate and evaporated. The residue was purified by silica gel column chromatography (ethyl acetate:n-hexane=3:7) to give the title compound (2.01 g) having the following physical data.
TLC: Rf 0.59 (n-hexane:ethyl acetate=1:1);
NMR: δ7.40-7.10 (12H, m), 6.93 (1H, s), 6.80-6.60 (3H, m), 5.35 (1H, s), 4.58 (2H, s), 4.03 (2H, t, J=7Hz), 3.79 (3H, s), 2.56 (2H, t, J=7Hz), 2.16(2 H, m).
EXAMPLE 17
3-[3-(4-diphenylmethylpyrazol-1-yl)propyl]phenoxyacetic acid ##STR114##
By the same procedure as in example 2, using the compound prepared in example 16 (1.5 g), the title compound (1.1 g) having the following physical data was given.
TLC: Rf 0.21 (chloroform:methanol=4:1);
IR [KBr tablet method] (cm -1 ): ν3027, 2930, 1736, 1586, 1493, 1451, 1219, 1159, 1079, 1014, 874, 753, 701, 507.
EXAMPLE 17(a)-17(dd)
By the same procedure as in reference example 9→example 16→example 17, using corresponding compounds, compounds having the following physical data shown in the table 5 were given.
TABLE 5__________________________________________________________________________EX.No. Structure of the example compound TLC IR.sub.(cm.spsb.-1.sub.)__________________________________________________________________________17(a)##STR115## Rf 0.26 (chloroform: methanol= ν 3027, 2936, 2861, 2517, 1736, 1586, 1494, 1451, 1374, 1219, 1158, 1079, 1015, 873, 753, 700, 635, 508, 47517(b)##STR116## Rf 0.19 (chloroform: methanol= ν 3029, 2932, 1737, 1587, 1494, 1452, 1373, 1242, 1160, 1080, 1032, 848, 780, 753, 70017(c)##STR117## Rf 0.15 (chloroform: methanol= ν 3028, 2929, 1736, 1586, 1494, 1452, 1216, 1160, 1079, 878, 754, 699, 63717(d)##STR118## Rf 0.14 (chloroform: methanol= ν 3029, 2929, 2508, 1736, 1586, 1493, 1454, 1222, 1160, 1114, 1081, 1032, 848, 751, 701, 639__________________________________________________________________________EX.No. Structure of the example compound TLC (Rf) NMR (δ)__________________________________________________________________________17(e)##STR119## 0.60 (methanol: methylene chloride= 1:4) 7.30-7.00(12H, m), 6.96(1H, s), 6.90-6.80(2H, m), 6.76(1H, d), 5.30(1H, s), 4.60(2H, s), 4.10(2H, t), 2.67(2H, t), 1.83(2H, m), 1.60(2H, m).17(f)##STR120## 0.63 (methanol: methylene chloride= 1:4) 7.50(1H, brs), 7.35-7.00(13H, m), 6.93(1H, s), 6.90(1H, t), 6.75(1H, d), 5.30(1H, s), 4.60(2H, s), 4.05(2H, t), 2.67(2H, t), 1.85(2H, m), 1.63(2H, m), 1.30(2H, m).17(g)##STR121## 0.19 (methanol: methylene chloride= 1:5) 7.4-7.0(12H, m), 6.82(2H, m), 6.72(1H, s), 6.67(1H, t), 6.0-4.8(1H, brs), 5.28(1H, s), .58(2H, s), 4.29(2H, t), 3.05(2H, t)17(h)##STR122## 0.33 (methanol: methylene chloride= 1:5) 8.0-7.2(1H, brs), 7.4-7.0(13H, m), 7.02(1H, s), 6.92(1H, t), 6.76(1H, d), 5.32(1H, s), 4.58(2H, s), 4.08(2H, t), 2.66(2H, t), 2.17(2H, tt)17(i)##STR123## 0.26 (chloroform: methanol= 4:1) 7.95(1H, brs), 7.36-7.13(12H, m), 7.05(1H, s), 6.96(1H, d), 6.92(1H, m), 6.78(1H, dd), 6.48(1H, d), 6.29(1H, dt), 5.33(1H, s), 4.82(2H, d), 4.56(2H, s).17(j)##STR124## 0.24 (methanol: methylene chloride= 1:5) (CDCl3CD3OD) 7.4-7.0(11H, m), 6.94(2H, d), 6.80(2H, d), 6.72(1H, s), 5.26(1H, s), 4.56(2H, s), 4.20(2H, t), 3.03(2H, t)17(k)##STR125## 0.26 (methanol: methylene chloride= 1:5) 7.5-7.1(11H, m), 7.01(2H, d), 6.95(1H, s), 6.82(2H, d), 5.34(1H, s), 4.58(2H, s), 4.07(2H, t), 2.49(2H, t), 2.08(2H, tt)17(l)##STR126## 0.28 (methanol: methylene chloride= 1:5) 7.5-7.1(11H, m), 7.02(2H, d), 6.96(1H, s), 6.82(2H, d), 6.6-5.6(1H, brs), 5.33(1H, s), .59(2H, s), 4.07(2H, t), 2.52(2H, t), 1.82(2H, m), 1.51(2H, m).17(m)##STR127## 0.17 (methanol: methylene chloride= 1:5) 7.4-7.3(12H, m), 7.05(1H, s), 6.9-6.7(3H, m), 5.32(1H, s), 5.20(2H, s), 4.58(2H, s).17(n)##STR128## 0.31 (chloroform: methanol= 4:1) 8.70-8.00(3H, m), 7.75-7.50(1H, m), 7.35-6.97(9H, m), 6.94-6.70(3H, m), 5.43(1H, brs), 5.60(2H, brs), 4.08(2H, m), 2.72(2H, m), 2.06-1.50(4H, m).17(o)##STR129## 0.16 (methanol: methylene chloride= 1:5) 8.47(2H, m), 7.61(1H, d), 7.40-7.13(8H, m), 7.09(1H, s), .00-6.80(3H, m), 6.43(1H, d), 6.27(1H, dt), 5.42(1H, s), 4.87(2H, d), 4.62(2H, s).17(p)##STR130## 0.29 (chloroform: methanol= 4:1) 7.36-7.13(11H, m), 6.95(1H, s), 6.94-6.70(4H, m), 5.33(1H, s), 4.75(2H, s), 4.03(2H, t), 3.84(3H, s), 2.50(2H, t), 2.20-2.02(2H, m).17(q)##STR131## 0.28 (methanol: methylene chloride= 1:5) 7.83(1H, d), 7.4-7.1(11H, m), 7.07(1H, s), 7.00(1H, dd), 6.97(1H, d), 6.6-5.8(1H, brs), .43(2H, m), 5.35(1H, s), 4.87(2H, m), 4.75(2H, s).17(r)##STR132## 0.22 (methanol: methylene chloride= 1:5) 8.02(1H, d), 7.40(1H, s), 7.4-7.1(11H, m), 7.07(1H, d,), .03(1H, d), 6.88(1H, dd), 6.32(1H, dt), 6.2-5.2(1H, brs), 5.36(1H, s), 4.90(2H, d), 4.68(2H, s).17(s)##STR133## 0.32 (chloroform: methanol= 4:1) 7.38-6.98(14H, m), 6.75(1H, d), 6.65(1H, t), 6.17(1H, dt), .44(1H, brs), 5.36(1H, s), 4.88(2H, d), 4.57(2H, s), 2.20(3H, s).17(t)##STR134## 0.38 (chloroform: methanol= 4:1) 7.38-7.00(13H, m), 7.00-6.60(1H, brs), 6.86(1H, d), 6.74(1H, s), 6.47(1H, d), 6.24(1H, dt), 5.32(1H, s), 4.79(2H, d), 4.62(2H, s), 2.24(3H, s).17(u)##STR135## 0.32 (chloroform: methanol= 4:1) 7.38-7.00(12H, m), 7.00-6.20(1H, brs), 6.78(1H, s), 6.70(1H, s), 6.63(1H, s), 6.43(1H, d), 6.26(1H, dt), 5.33(1H, s), 4.81(2H, d), 4.56(2H, s), 2.26(3H, s).17(v)##STR136## 0.31 (chloroform: methanol= 4:1) 7.40-6.90(14H, m), 6.74(1H, dd), 6.63(1H, d), 6.40(1H, brs), 6.20(1H, dt), 5.35(1H, s), 4.85(2H, d), 4.57(2H, s), 2.20(3H, s).17(w)##STR137## 0.40 (methanol: methylene chloride= 1:4) 8.63 and 8.47(1H, s), 8.56 and 8.53(1H, d), 7.78-7.73 and 7.62-7.37(1H, m), 7.45-7.22(6H, m), 7.16-7.09(1H, m), 6.79-6.65(3H, m), 4.43(2H, s), 4.38-4.33(2H, m), 2.96-2.88(2H, m)17(x)##STR138## 0.49 (methanol: methylene chloride= 1:4) 8.71 and 8.62(1H, s), 8.61 and 8.55(1H, d), 7.80-7.76 and 7.70-7.67(1H, m), 7.50-7.25(6H, m), 7.13-7.06(1H, m), 6.75-6.65(3H, m), 4.45(2H, s), 4.20-4.10(2H, m), 2.60-2.50(2H, m), 2.01-1.92(2H, m)17(y)##STR139## 0.46 (methanol: methylene chloride= 1:4) 8.81 and 8.67(1H, s), 8.57 and 8.52(1H, d), 7.73-7.65(1H, m), .50-7.20(6H, m), 7.10-7.05(2H, m), 6.85(1H, t), 6.73(1H, d), 4.51 and 4.48(2H, s), 4.25-4.18(2H, m), 2.75-2.65(2H, m), 2.10-1.98(2H, m)17(z)##STR140## 0.46 (methanol: methylene chloride= 1:4) 8.71 and 8.62(1H, s), 8.55 and 8.52(1H, d), 7.78-7.74 and 7.70-7.66(1H, m), 7.47-7.15(6H, m), 7.13-7.08(2H, m), 6.88(1H, t), 6.74(1H, d), 4.54(2H, s), 4.25-4.18(2H, m), 2.73-2.65(2H, m), 1.80-1.60(4H, m).17(aa)##STR141## 0.43 (methanol: methylene chloride= 1:4) 8.72 and 8.64(1H, s), 8.59-8.50(1H, m), 7.78-7.73 and 7.68-7.65(1H, m), 7.46-7.15(6H, m), 7.14-7.07(2H, m), 6.90-6.85(1H, m), 6.78-6.73 (1H, m), 4.52(2H, s), 4.18(2H, t), 2.67(2H, t), 1.80-1.69(2H, m), 1.69-1.56(2H, m), 1.44-1.34(2H, m)17(bb)##STR142## 0.22 (methanol: methylene chloride= 1:5) 8.80(0.4H, d), 8.70(0.6H, d), 8.67(0.6H, dd), 8.62(0.4H, dd), 7.87-7.72(1H, m), 7.60-6.90(9H, m), 6.90-6.78(1H, m), 6.63(0.4H, d), 6.55(0.6H, d), 6.37(0.6H, dt), 6.30(0.4H, dt), 4.92-4.77(2H, m), 4.67(0.8H, s), 4.65(1.2H, s).17(cc)##STR143## 0.19 (methanol: methylene chloride= 1:5) 7.4-7.0(12H, m), 6.8-6.0(5H, m), 5.32(1H, s), 4.58(2H, s), 4.44(2H, t), 4.24(2H, t)17(dd)##STR144## 0.43 (methanol: methylene chloride= 1:4) 8.67 and 8.57(1H, s), 8.56 and 8.53(1H, d), 7.77-7.73 and 7.70-7.65(1H, m), 7.45-7.25(6H, m), 7.13-7.06(1H, m), 6.55-6.45(3H, m), 4.55-4.40(4H, m), 4.25-4.15 (2H,__________________________________________________________________________ m)
The example compounds shown in table 5 are named as follows:
17(a) 3-[4-(4-Diphenylmethylpyrazol-1-yl)butyl]phenoxyacetic acid,
17(b) 3-[3-(4-Diphenylmethyl-1,2,3-triazol-2-yl)propyl]phenoxyacetic acid,
17(c) 3-[3-(4-Diphenylmethyl-1,2,3-triazol-1-yl)propyl]phenoxyacetic acid,
17(d) 3-[3-(4-Diphenylmethyl-1,2,3-triazol-3-yl)propyl]phenoxyacetic acid,
17(e) 2-[4-(4-Diphenylmethylpyrazol-1-yl)butyl]phenoxyacetic acid,
17(f) 2-[5-(4-Diphenylmethylpyrazol-1-yl)pentyl]phenoxyacetic acid,
17(g) 3-[2-(4-Diphenylmethylpyrazol-1-yl)ethyl]phenoxyacetic acid,
17(h) 2-[3-(4-Diphenylmethylpyrazol-1-yl)propyl]phenoxyacetic acid,
17(i) 3-[3-(4-Diphenylmethylpyrazol-1-yl)-1-propenyl]phenoxyacetic acid,
17(j) 4-[2-(4-Diphenyimethylpyrazol-1-yl)ethyl]phenoxyacetic acid,
17(k) 4-[3-(4-Diphenylmethylpyrazol-1-yl)propyl]phenoxyacetic acid,
17(l) 4-[4-(4-Diphenylmethylpyrazol-1-yl)butyl]phenoxyacetic acid,
17(m) 3-[(4-Diphenylmethylpyrazol-1-yl)methyl]phenoxyacetic acid,
17(n) 2-[4-(4-Diphenylmethylpyrazol-1-yl)butyl]phenoxyacetic acid,
17(o) 3-[3-[4-[1-Phenyl-1-(3-pyridyl)methyl]pyrazol-1-yl]-1-propenyl]phe noxy acetic acid,
17(p) 2-Methoxy-5-[3(4-diphenylmethylpyrazol-1-yl)propyl]phenoxyacetic acid,
17(q) 2-Nitro-5-[3-(4-diphenylmethylpyrazol-1-yl)-1-propenyl]phenoxyacetic acid,
17(r) 4-Nitro-3-[3-(4-diphenylmethylpyrazol-1-yl)-1-propenyl]phenoxyacetic acid,
17(s) 2-Methyl-3-[3-(4-diphenylmethylpyrazol-1-yl)-1-propenyl]phenoxyacetic acid,
17(t) 2-Methyl-5-[3-(4-diphenylmethylpyrazol-1-yl)-1-propenyl]phenoxyacetic acid,
17(u) 3-Methyl-5-[3-(4-diphenylmethylpyrazol-1-yl)-1-propenyl]phenoxyacetic acid,
17(v) 4-Methyl-3-[3-(4-diphenylmethylpyrazol-1-yl)-1-propenyl]phenoxyacetic acid,
17(w) 3-[2-[1-Phenyl-1-(3-pyridyl)methylideneaminooxy]ethyl]phenoxyacetic acid,
17(x) 3-[3-[1-Phenyl-1-(3-pyridyl)methylideneaminooxy]propyl]phenoxyacetic acid,
17(y) 2-[3-[1-Phenyl-1-(3-pyridyl)methylideneaminooxy]propyl]phenoxyacetic acid,
17(z) 2-[4-[1-Phenyl-1-(3-pyridyl)methylideneaminooxy]butyl]phenoxyacetic acid,
17(aa) 2-[5-[1-Phenyl-1-(3-pyridyl)methylideneaminooxy]pentyl]phenoxy acetic acid,
17(bb) 3-[3-[1-Phenyl-1-(3-pyridyl)methylideneaminooxy]-1-propenyl]phenoxy acetic acid,
17(cc) 3-[2-(4-Diphenylmethylpyrazol-1-yl)ethyloxy]phenoxyacetic acid and
17(dd) 3-[2-[1-Phenyl-1-(3-pyridyl)methylideneaminooxy]ethyloxy]phenoxy acetic acid.
EXAMPLE 18
Methyl 3-[3-(5-diphenylmethylisoxazol-3-yl)propyl]phenoxyacetate ##STR145##
To a suspension of the compound prepared in reference example 16 (300 mg), potassium bicarbonate (138 mg)in dimethylformamide (4.0 ml) was added dropwise and methyl bromoacetate (0.095 ml) was added with stirring at room temperature. The mixture was stirred for 5 h at 50° C. The mixture was poured into water and extracted with ethyl acetate. The extract was washed with water and saturated aqueous solution of sodium chloride, successively, dried over anhydrous magnesium sulfate and evaporated. The residue was purified by silica gel column chromatography (benzene:ethyl acetate=19:1) to give the title compound (350 mg) having the following physical data.
TLC: Rf 0.22 (ethyl acetate:n-hexane=1:3);
NMR: δ7.37-7.02 (11H, m), 6.85-6.67 (3H, m), 5.72 (1H, s), 5.51 (1H, s), 4.62 (2H, s), 3.79 (3H, s), 2.72-2.57 (4H, m), 2.05-1.86 (2H, m).
EXAMPLE 19
3-[3-(5-diphenylmethylisoxazol-3-yl)propyl]phenoxyacetic acid ##STR146##
To a solution of the compound prepared in example 18 (295 mg) in tetrahydrofuran (2.0 ml) and methanol (1.0 ml) was added dropwise 1N aqueous solution of sodium hydroxide (1.0 ml) with stirring at room temperature. After being stirred for 30 min at room temperature, the mixture was neutralized by addition of 1N hydrochloric acid and was extracted with ethyl acetate. The extract was washed with water and a saturated aqueous solution of sodium chloride successively, dried over anhydrous magnesium sulfate, and evaporated. The residue was purified by silica gel column chromatography (chloroform:methanol=49:1→9:1) to give the title compound (208 mg) having the following physical data.
TLC: Rf 0.25 (chloroform:methanol=4:1);
IR [KBr tablet method] (cm -1 ): ν3401, 3028, 2924, 1796, 1494, 1452, 1425, 1340, 1248, 1160, 1078, 900, 791, 752, 699.
EXAMPLE 19(a)-19(b)
By the same procedure as in reference example 14→reference example 16→example 18→example 19, using the compound prepared in reference example 23 and by the same procedure as in reference example 16 →example 18→example 19, using the compound prepared in reference example 25, compounds having the following physical data shown in the table 6 were given.
TABLE 6__________________________________________________________________________EX.No. Structure of the example compound TLC (Rf) NMR (δ)__________________________________________________________________________19(a) ##STR147## 0.14 (chloroform: methanol= 9:1) 7.4-6.5(1H, brs), 7.38-7.14(11H, m), 6.82(1H, d), 6.77-6.72(2H, m), .81(1H, s), 5.55(1H, s), 4.65(2H, s), 2.71(2H, t), 2.65(2H, t), 2.09-1.92(2H, m).19(b) ##STR148## 0.19 (chloroform: methanol= 17:3) 7.35-7.12(11H, m), 6.84-6.69(4H, m), 5.97(1H, brs), 5.66(1H, s), 4.64(2H, s), 2.85(2H, t), 2.64(2H, t), 2.08-1.90(2H,__________________________________________________________________________ m).
The example compounds shown in table 6 are named as follows:
19(a) 3-[3-(3-Diphenylmethylisoxazol-5-yl)propyl]phenoxyacetic acid and
19(b) 3-[3-(3-Diphenylmethylisothiazol-5-yl)propyl]phenoxyacetic acid.
EXAMPLE 20
Methyl 3-[3-(3-diphenylmethyl-1,2,4-oxadiazol-5-yl)propyl]phenoxy acetate ##STR149##
A solution of the compound prepared in reference example 17 (193 mg) in toluene (8 ml) was refluxed overnight. The mixture was evaporated. The residue was purified by flash silica gel chromatography (n-hexane:ethyl acetate=4:1) to give the title compound (108 mg) having the following physical data.
NMR: δ7.40-7.10 (11H, m), 6.90 (1H, d, J=7Hz), 6.75 (1H, s), 6.72 (1H, d, J=7Hz), 5.58(1H, s), 4.60 (2H, s), 3.79 (3H, s), 2.87 (2H, t, J=7Hz), 2.67 (2H, t, J=7Hz), 2.11 (2H,m);
MS(m/z): 442 (M + ), 250, 167.
EXAMPLE 21
3-[3-(3-diphenylmethyl-1,2,4-oxadiazol-5-yl)propyl]phenoxyacetic acid ##STR150##
By the same procedure as in example 2, using the compound prepared in example 20 (108 mg), the title compound (102 mg) having the following physical data was given.
TLC: Rf 0.16 (chloroform:methanol=9:1);
NMR: δ7.40-7.10 (11H, m), 6.90-6.70 (3H, m), 5.59 (1H, s), 4.62 (2H, s), 2.87 (2H, t, J=7Hz), 2.68 (2H, t, J=7Hz), 2.12 (2H, m).
EXAMPLE 22
Methyl 3-[3-(5-diphenylmethyl-1,2,4-oxadiazol-3-yl)propyl]phenoxy acetate ##STR151##
A solution of the compound prepared in reference example 20 (61 mg) in toluene (8.0 ml) was refluxed overnight. The mixture was evaporated. The residue was purified by flash silica gel chromatography (n-hexane:ethyl acetate=4:1) to give the title compound (31 mg) having the following physical data.
NMR: δ7.40-7.10 (11H, m), 6.82 (1H, d, J=7Hz), 6.78 (1H, s), 6.74 (1H, d, J=7Hz), 5.70 (1H, s), 4.60 (2H, s), 3.80 (3H, s), 2.76 (2H, t, J=7Hz), 2. J=7Hz), 2.08 (2H, m);
MS (m/z): 442 (M + ), 251, 167.
EXAMPLE 23
3-[3-(5-diphenylmethyl-1,2,4-oxadiazol-3-yl)propyl]phenoxyacetic acid ##STR152##
By the same procedure as in example 2, using the compound prepared in example 22 (31 mg), the title compound (30 mg) having the following physical data was given.
TLC: Rf 0.18 (chloroform:methanol=9:1);
NMR: δ7.40-7.10 (11H, m), 6.84(1H, d, J=7Hz), 6.77(1H, s), 6.74 (1H, d, J=7Hz), 5.72 (1H, s), 4.63 (2H, s), 2.74 (2H, t, J=7Hz), 2.67 (2H, t, J=(2H, m).
Formulation example 1
The following components were admixed in a conventional method and punched out to obtain 100 tablets each containing 5 mg of active ingredient.
______________________________________3-(4-Diphenylmethyloxyiminobutyl)phenoxy 500 mgacetic acidCarboxymethylcellulose calcium 200 mgMagnesium stearate 100 mgMicrocrystalline cellulose 9.2 g______________________________________
Formulation example 2
The following components were admixed in a conventional manner. The solution was sterilized in conventional manner, portions were placed 5 ml into 10 ml ampoules and freeze-dried to obtain 100 ampoules each containing 2 mg of the active ingredient.
______________________________________3-(4-Diphenylmethyloxyiminobutyl)phenoxy 200 mgacetic acidCitric acid, anhydrous 20 mgDistilled water 500 ml______________________________________
"While the invention has been described in detail and with reference to specific examples thereof, it will be apparent to one skilled in the art that various changes and modifications can be made therein without departing from the spirit and scope thereof." | We proposed a novel compound having an activity of PGI 2 receptor agonist.
A phenoxyacetic acid derivative of the formula ##STR1## A is --C(R 1 )═N˜OR 2 , --CH(R)NH--OR 2 , --COE, --SO 2 E, --CH 2 --NR 3 --Y, --Z -- NR 3 --CONR 4 R 5 , --CH 2 --OR 6 , --CO 2 R 6 , --CH 2 --O˜N═CR 7 R 8 , --CH 2 --O--NHCHR 7 R 8 , substituted by imidazolyl(methyl), pyrazolylmethyl, oxazolyl(methyl), thioxazolyl, isoxazolyl, isothiazolyl, oxadiazolyl, triazolylmethyl;
T is alkylene, alkenylene, etc.;
D is --CO 2 R 10 , --CONR 11 R 12 ;
E is (substitution) amino, hydradino;
Y is substituted (thio) carbonyl, substituted sulfonyl;
Z is --CH═N--, --CH 2 NR 3 --;
R 1 , R 3 , R 10 -R 13 is each H or alkyl, etc.;
R 2 , R 4 -R 9 is each H, alkyl or alkyl substituted by phenyl or hetero ring, etc. and non-toxic salts thereof, non-toxic acid addition salts thereof, possess an agonistic on PGI 2 receptor, so it is useful for prevention and/or treatment of thrombosis, arteriosclosis, ischemic heart diseases, gastric ulcer and hypertention. | 2 |
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